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ome coincidences would rather never occur. It is no coincidence that everybody seems to have got into the habit of comparing India with China in everything that is done and in this regard, we have come a long way in comparing everything possible…from bursting population to buzzing economies—the two aspects that these two countries epitomise. As we go to press, another leaf is added to this comparison and the coincidence chapter, with the occurrence of two ill-fated incidences that happened within a gap of 96 hours.

Dateline Jalandhar: At least one person was killed and more than 90 feared trapped under debris after a four-storeyed blanket factory building collapsed following a blast in the factory’s boiler.

Dateline Beijing: Seven workers remained trapped in a flooded coal mine in eastern China. The incident took place at the Kongzhuang coal mine in Jiangsu province when the flooding occurred.

Trapped is the dreaded word for more reasons than one. Most primitively, in this context, it threatens to cut the precious life of the trapped workers. But if you analyse the above two incidences analytically, devoid of any emotion, it is also about trapped productivity and profitability. Reason? One such incident and all that you have been preserving so painstakingly for so long becomes dust in no time, be it man or machine. The question is, is it worth it?

Nobody angles for disaster. But most of us flout safety and security measures, in different magnitudes, thinking that accidents always happen to somebody else. Before this incident, the blanket factory owner in Jalandhar and the mine contractor in Bejing also shared a similar belief. So, since there is never an apt time than now to take safety and security seriously, we decided to dedicate this edition of SEARCH to this very critical, yet sometimes ignored, aspect of your manufacturing practice.

While it is critical for your very being, i.e., your existence, it is also a great business strategy. In this day and age of talent crunch, a safe and secure working environment not only adds to your traction quotient for talent, but also helps to spread positivity, as the workers feel secure, and we know the power of positivity!

So, as you get serious about safety, we provide you with a satiating spread of content, with topics ranging from enhanced safety needs in automated facilities and safety incentive mechanism to safety leadership imperatives and, not to forget, some new age safety gears. You will be spoilt for choice with leaders like TATA Power talking about how they aim and achieve a zero-incident workplace.

So, while you gain knowledge and inspiration from the experts, the products and services spread updates you about the latest technology, equipment, products and services. Not only this, our new initiatives aims to help you optimise and ease your sourcing needs. Check the details in this edition for more information.

Help is at hand…reach out, be safe and secure your productivity & profits!!

STRAPPED POTENTIAL?

Archana [email protected]

EDITORIAL

| Pg 54

CONTENTS

11 EDITORIAL Trapped Potential?

SPECIAL FOCUS: Safety & Security

AUTOMATION TRENDS94 Development Dynamics Gearing Up To Enter New Growth Avenues

Comes FirstThe repercussions of the Bhopal gas tragedy that occurred 27 years ago are still clearly evident in and around Bhopal. So far, various unwanted incidents have occurred in manufacturing units across India. While some have come to light, many others remain unreported. But yes, based on our experience of industrial visits, it is clear that safety at Indian manufacturing facilities has come a long way. As India establishes itself as an economic superpower, it is still catching up with the rest of the world in terms of improving the working conditions of millions of its workers.

NEWS, VIEWS & ANALYSIS38 Latest Happenings In The World Of Manufacturing

ENERGY MANAGEMENT96 Photovoltaic Modules’ Lifecycle Management Powering Sustainability ‘We Believe In

Technology And Price Leadership’ Dr Gunther Kegel, CEO, Pepperl+Fuchs GmbH

PPg 46g 46

IN CONVERSATION WITH

TECHNOLOGY & INNOVATIONS44 Technology Update Cutting-edge Solutions

FACILITY VISIT90 Tata Power Taking An Integrated Approach Towards Safety

POLICIES & REGULATIONS100 Union Budget 2012–13 An Attempt Towards Striking Balanced Growth

� Special Focus: Switchgears� Insights & Outlook: Motors

� Special Edition: Investment Destination: Aurangabad

HIGHLIGHTS: JUNE 2012

STRATEGY105 Safety Leadership Implementing A Top-down Approach

TIPS & TRICKS108 Safety & Security 10 Ways To Make Your Workplace Mishap-free

Safety

PRODUCT UPDATE

CONTENTSSPECIALS IN THIS ISSUE

180 ADVERTISERS’ LIST Advertisers’ List In Chronological Order

PRODUCT UPDATE110 New Launches Latest Products In The Offing

118 Safety & Security Latest Products In Safety & Security

126 Wires & Cables Latest Products In Wires & Cables

138 General Products Rolling Out The Best In Class

159 International Products Showcasing Products In A Global Arena

SPECIAL FOCUSSafety & Security

Opinions & More

52 ‘Safety Should Be Made Part Of An Organisation’s Culture’

Vipul Shah, President, CEO & Chairman, Dow Chemical International Pvt Ltd

58 Industrial Safety & Security Innovative Technologies

Popularise Safety Gears

60 Safety & Automation Achieving Zero-incident

Workplace Through Automation

166 EVENTS LIST

INSIGHTS & OUTLOOK

74 Industry Dynamics Critical Nerve Centre For

Manufacturing

76 Wires & Cables Opportunities Transmitting Waves Of Growth

80 Wires And Cables Outlook Are We Heading Towards A

Wireless Future?

84 Power Cables Maintenance Is Better Than Repair

170 PRODUCT INDEX Alphabetical Listing Of Products Presented In The Issue

64 Safety Incentive Mechanism

Securing Workplaces

66 Safety & Security Market Overview

Capitalising On The Burgeoning Growth

70 Security In Data Traffic Building A Secure

Firewall

REPORT168 Modern Machine Shop 2012 Maximising Metalworking Scope

Looking For A Specifi c Product?Searching and sourcing products were never so easy.

Just type SRCH (space) Product Name

and send it to 51818eg. SRCH Pump and send it to 51818

Human error in operations and maintenance remains a major contributor to industrial risk & the unconscious belief, that we cannot do much about human unpredictability and unreliability, is promoting industrial incidents and accidents. Information dissemination, real-time information on all available services and the creation of a system to examine various safety systems in industries are among the key requirements for disaster management and mitigation.

According to CII, India had to face over 430 natural and man-made disasters in the last decade. Each of them, on an average, had a toll of over 4,500 people. About five crore people were being affected every year. Disaster preparedness and management were most important and the tools of information and communication technology had to be put to maximum use. In light of the above, it is inevitable that many manufacturers will begin taking a closer look at safety and security practices in their own facilities & examine ways to ensure that their people and processes are adequately protected.

Suppliers have made great strides in building this defence, and a small percentage of top tier, enlightened suppliers of control systems and customers are applying best practices to this ‘problematic’ area. New and matured technologies are available and are being evolved for defending and protecting control system assets. The ideal safety system in today’s manufacturing environments would not only alert personnel to abnormal situations, but also provide better overall awareness of the operating environment. This will prevent more incidents from escalating into disastrous incidents that put lives at risk. And when one does happen, the goal is to mitigate further damage and to develop the appropriate response so that the condition can return to normal as safely and quickly as permissible.

Along the lines of providing better overall awareness to plant personnel, another potential avenue for improving the overall safety system is tying it together with other critical functions. The past few years, for instance, have seen increased discussion regarding whether plants should integrate their safety and security systems with process control. While these functions historically have remained separate, the trend draws interest for its ability to improve overall awareness of activities throughout a plant.

The bottom line is always literally and figuratively the same as in manufacturing. These days, the issue of plant safety is being closely scrutinised as something that affects the bottom line—especially in a tight economy. It is one thing to work on margins, but when plants have to start paying out everything from facility repairs to personal injury claims, things can turn unprofitable very quickly. As such, industrial safety is now viewed as a way of not only protecting people while mitigating damage and protecting assets; it is also being seen as a way to protect a plant’s profitability, and a way to return a plant to profitability as quickly as possible following an incident.

PROTECTING PEOPLE, PROCESSES AND PROFITABILITY

GUEST EDITORIAL

Amitava BiswasCountry Manager, Honeywell Process

Solutions India

In his current role, Amitava Biswas is responsible for the strategic business

development, performance and

operations of Honeywell Process Solutions in

India. Formerly, he was Director – Integrated

Supply Chain, Honeywell Automation

India Ltd.With over 25 years of

experience in industrial automation and

systems, he has spent the greatest part of his

career at Honeywell since 1991. Since then,

Amitava’s career has moved through various

roles in engineering, vertical market leadership and

management across Honeywell’s businesses

in India. Amitava holds a

Bachelor’s Degree in Technology from IIT

Kanpur.

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38 SEARCH - THE INDUSTRIAL SOURCEBOOK | M A Y 2 0 1 2

NEWS, VIEWS & ANALYSISNEWS, VIEWS & ANALYSISL A T E S T H A P P E N I N G S I N T H E W O R L D O F M A N U F A C T U R I N G

The growth in February’s Index of Industrial Production (IIP) has come in at 4.1%—an improvement over the January figure. The January IIP figure has been revised to 1.1% from 6.8% (provisional). The Central Statistical Organization revised the January IIP figure after it spotted an error in the sugar output figures. Manufacturing output, which constitutes nearly 76% of the total industrial production, declined to 4% vs 7.5% year-on-year. The mining sector growth, which has been underperforming for a while, has come in at 2%. While the capital goods index, at 10.6% is an improvement month-on-month; consumer non-durables growth in February stands at 5%.

The core sector, which contributes almost 38% to industrial production, grew by a sharp 6.8% in February from a year earlier. Core sector comprises key infrastructure industries of coal, crude oil, natural gas, refinery products,

fertilisers, steel, cement and electricity.According to A Prasanna,

Economist, ICICI Securities Primary Dealership Ltd, “The data confirms that the IIP growth is in trend with the yearly growth of 4%. But the data is not good at all as even after the growth bottomed out in the third quarter (October–December), the recovery is not really picking up on the demand side. Such higher interest rates in the economy will affect the demand-side improvement.” “From RBI’s policy perspective, we still think that there is scope for 25 basis point rate cut in April. Since inflation is moderating only on the margin, and growth in 2012–13 is expected to be, according to RBI’s trend line of 7%, there is not much scope for bigger rate cuts,” he added.

On the similar lines, Sujan Hajra, Chief Economist, Anand Rathi Securities, Mumbai, says, “We were

expecting a better figure, i.e., above 6%. Overall, this is disappointing, but our sense is that irrespective of IIP, RBI will go ahead with a 25 basis point rate cut at the upcoming policy decision.”

On the other hand, Chandrajit Banerjee, Director General, CII, is of the view that the IIP figures for February 2012 are along expected lines, with moderate improvements being seen in basic goods and capital goods with base effect also playing a part. However, the error reported in the January figures has sharply pulled down the growth rate for the year till now. Overall, industrial growth remains weak and is not likely to exceed 4% in FY2012. In order to realise the Budget projection of 7.6% GDP growth in FY2013, it is necessary to use all policy levers to encourage growth and investment. It is high time RBI focusses on getting growth back by sharply reducing interest rates.

FEBRUARY 2012 IIP GROWTH STANDS AT 4.1%

Indofil has recently entered into a landmark joint venture (JV) with Shanghai Baijin Chemical Group (SBC), China, for CS2 manufacturing through a 51:49 partnership in Indo Baijin Chemicals Pvt Ltd. The approximate US$40-million plant would be the first in the country to use eco-friendly technology for CS2 production.

Commenting on the occasion, KK Modi, Chairman & MD, Indofil Industries Ltd, informed, “At present, 80% of India’s CS2 is imported from various parts of the world. I hope this unit would substitute for some of these imports. By adopting eco-friendly technology in production, Indofil will set an example in the chemical industry for sustainable development.”

Indo Baijin Chemicals Pvt Ltd is the first Indo-Chinese JV for the Modi Group to establish an annual production capacity of 50,000 tonne of CS2, using ‘Green Technology’.

Speaking on the technology, Modi said, “The proposed plant will have ‘zero’ wastage discharge. The plant will recycle 300 cubic metre water per day and recover 135 tonne steam per day from waste heat.”

Modi added, “Preliminary evaluations indicate that the project will be entitled for 25,000 tonne of carbon credit per year. With this state-of-the-art green technology, charcoal will be replaced by natural gas. This will help us save 50,000 tonne of wood per year, which is equivalent to 58 sqkm of forest.”

According to RK Malhotra, Chief Executive & President, Indofil Industries Ltd, “The setting up of this unit is a key strategic move to ensure consistent supply of CS2. CS2 is a key raw material for our products, which include Mancozeb. Through this backward integration, we would be able to strengthen Indofil’s supply chain.”

INDOFIL INDUSTRIES TIES-UP WITH SHANGHAI BAIJIN, CHINA

Caterpillar India recently launched a new backhoe loader manufacturing facility in Thiruvallur, near Chennai. The new facility, not only strengthens the company’s growing presence in India, but also augments its distribution channel by bringing in enhanced local production capabilities. Robert Droogleever, GM, Caterpillar BHL Worldwide, said, “Our new facility is a testimony to the growing importance that India, as a market, commands in our global backhoe loader business strategy.”

Kevin Thieneman, Country Manager – India, ASEAN & China, said, “India will make significant investments over the next decades to build its infrastructure and support higher levels of urbanisation. This facility, our fourth manufacturing operation in India, enables us to better serve our customers with the broadest range of products in the industry.”

CATERPILLAR EXPANDS INDIAN PRESENCE

NEWS, VIEWS & ANALYSISL A T E S T H A P P E N I N G S I N T H E W O R L D O F M A N U F A C T U R I N G


With the recent introduction of its new Attune™ Advisory Services, Honeywell promises to offer a suite of professional services that combines cloud-based tools and analytics with a global network of operations centres and energy & facility experts to provide enhancements that can reduce utility bills and operating expenses up to 20%.

“The performance of building systems and equipment can degrade by as much as 5% every year, which translates into energy and operating costs that continually escalate,” said Paul Orzeske, President, Honeywell Building Solutions, adding, “Companies are starting to realise the significant impact that this can have, as well as the opportunity it presents for bottom-line savings. With Attune, we are providing the ease and convenience of cloud-based technology with expert advice and actionable guidance so that companies can capture & maintain those savings.”

According to the International Energy Agency (IEA), buildings account for nearly 40% of energy used

in most countries. Many barriers work against energy efficiency in buildings, including lack of useful information. These services turn building performance data into an action plan that pinpoints potential upgrades and their expected return on investment.

The service suite enables facility managers to optimise their budgets, personnel and systems by combining powerful cloud-based tools & analytics with insight and advice from a global team of Honeywell consultants.

HONEYWELL’S NEW INITIATIVE AIMS TO CUT ENERGY & OPERATING COSTS

Cloud-based, Software-as-a-Service Technology provides easy access to sophisticated monitoring & analysis, and Honeywell specialists

Recommended building improvements delivered by skilled technicians

Online and onsite expertise combine to trim facility expenses upto 20%.

USPs

CynarPlc, a leading technology company in the waste-to-energy market, has awarded an $11 million contract to Rockwell Automation to design and build a new end-of-life, plastic-to-fuel conversion plant in Bristol, UK, for SITA UK Ltd. Cynar has developed a technology that converts end-of-life plastics into fuel.

According to Michael Murray, CEO & Chairman, CynarPlc, “Our technology represents a unique and profitable way to significantly decrease the amount of end-of-life plastics that are disposed of in landfills and incinerators.”

Hedwig Maes, President, Rockwell Automation Europe, Middle East and Africa Region, said, “This agreement

with Cynar demonstrates Rockwell Automation’s ability to deliver scalable, complex solutions on a global level. We are pleased to work with Cynar in an industry that is making the world more sustainable.”

Terry Gebert, VP & GM, Rockwell Automation Global Solutions, said, “This win is significant for us in the waste-to-energy market.”

“It includes the design and build of process skids, automation architecture, software, power control and engineering/startup services in one fully integrated solution, using the Rockwell Automation PlantPAxProcess Automation System. With this contract award, Rockwell Automation will enter the design and build phase of the project,” Gebert added.

CYNARPLC AWARDS $11 MILLION WASTE-TO-ENERGY PROCESS ORDER TO ROCKWELL AUTOMATION

Suzlon Group recently signed a global strategic partnership agreement with CGN Wind Energy Co Ltd (CGNWE), which is a wholly owned subsidiary of China Guangdong Nuclear Power Group—one of the largest wind power developers in China, with installed capacity of around 3,000 MW. The agreement calls for the development of 800 MW of domestic and international projects over the next three years. A working team has been set up to explore the most viable projects globally, covering countries such as Brazil, South Africa, India and China.

Speaking on the partnership, Chensui, Chairman, CGNWE, said, “With Suzlon’s experience in the global market and CGNWE’s expertise in wind power, we are confident of building successful projects to meet the renewable energy needs.” Tulsi Tanti, Chairman, Suzlon Group, said, “We hope that Suzlon’s experience in across 32 markets worldwide will be valuable for CGNWE in its endeavour to operate wind farms globally.”

Meanwhile, Cennergi, a joint venture by Exxaro and Tata Power has also selected Suzlon turbines for the 138 MW project bid in South Africa. Suzlon will provide 66 of Suzlon’s S97-2.1 MW turbines for Cennergi’s 138 MW wind energy project currently under development at Eastern Cape Province, South Africa. If definitive agreements are reached, Suzlon will deliver the turbines under a full EPC agreement. Speaking on the partnership, Thomas Garner, CEO, Cennergi, said, “Suzlon was an obvious choice based on its vast experience in emerging markets.” The project construction is expected to commence towards 2013.

SUZLON SIGNS DEAL WITH CHINESE & SOUTH AFRICAN

COMPANIES

NEWS, VIEWS & ANALYSIS

NEWS, VIEWS & ANALYSISL A T E S T H A P P E N I N G S I N T H E W O R L D O F M A N U F A C T U R I N G


NEWS, VIEWS & ANALYSIS

Putting US-India trade relationship at the cornerstone of global business, John Bryson, Commerce Secretary, US Department of Commerce, recently said, “President Obama had stated that the US-India business relationship is one of the defining relationships of the 21st century.” He was addressing an exclusive session with the captains of the Indian industry organised by the Confederation of Indian Industry (CII) in Mumbai.

Travelling with a delegation of 16 businesses, Bryson said, “With your phenomenal growth, millions have risen out of poverty. Your growth has led to the increased demand for US products with US exports growing from less than $4 billion in 2001 to over $21 billion last year. America has reciprocated this with the US receiving $36 billion of goods & services from

India last year. With your aggressive plan of investing $1 trillion only in infrastructure and over 600 major projects, we want our partnership to deepen further for mutual profit.”

He reiterated, “Reform is happening in the American Tax Code. We have one of the highest statutory corporate tax for any country that has only become more complicated since the 1980s. We are lowering the corporate tax from 35% to 28%.” Elaborating further, he added, “Our two democratic countries are serious global business leaders in the 21st century, who are jointly committed to fairness, openness, transparency and level playing field.”

B Muthuraman, President, CII & Vice Chairman, Tata Steel Ltd, said, “CII recognises that trade and investment is a two-way street and we want to make this street between India

and US into a superhighway. CII strongly supports businesses conducive to the growth of business in both the countries.”

Ajay Piramal, Chairman, Piramal Group, said, “India has much to offer to American businesses. In addition to capital, we offer the ability to access emerging market and we would add value to your business. We are no longer in the ‘BPO’ mode, but have gone ahead and acquired Chapter 11 businesses and turned them around.”

Chandrajit Banerjee, Director General, CII, said, “US is a natural partner as we share many common characteristics. There are many promising opportunities, but there are challenges as well. At CII, we believe in converting these challenges into opportunities. We are with you in pushing bilateral trade.”

WORLD’S TWO LARGEST DEMOCRACIES WORK TO BUILD THE STRONGEST GLOBAL BUSINESS RELATIONSHIP

Reliance Power Ltd, a Reliance ADA Group company, has been successful in commissioning a 40 MW (AC) ground-mounted solar photovoltaic (PV) power plant in Rajasthan.

Reliance Power has utilised 5,00,000 thin-film modules from First Solar, a premier provider of comprehensive PV system solutions in this plant, located near Dhursar in Jaisalmer, Rajasthan. The plant is expected to generate more than 60 million kilowatt hours (kwh) of clean solar energy a year, making it one of the country’s largest PV power plant in terms of electricity generation.

Covering 350 acre, this plant is also expected to satisfy the annual electricity needs of more than 70,000 average Indian households. It will displace more than 60,000 metric tonne of carbon dioxide (CO

2) emissions per

year, the equivalent of taking more than 25,000 cars off the road.

The recently completed project was built in a span of just five months. It is the first of the several plants that

Reliance plans to build with First Solar modules as part of a 100 MW module order placed in 2011.

Commenting on the necessity of developing solar infrastructure, Anil D Ambani, Chairman, Reliance Power, said, “This power plant demonstrates the huge potential of solar energy to help India meet its growing energy needs in the most environmentally friendly manner.”

Mike Ahearn, Chairman & Interim CEO, First Solar, is a proud partner in this project. Ahearn said, “We applaud India on its visionary solar policies and Reliance Power for their leadership in implementing them. We look forward to helping India realise its solar vision through this and several other future projects.”

The Indian solar market is expected to be spurred in 2012 by the maturing National Solar Mission, a collection of state-level incentives, and the influx of expertise from global solar players entering the Indian market.

RELIANCE POWER COMMISSIONS INDIA’S LARGEST SOLAR POWER PLANT IN RAJASTHAN

Reinforcing the view that China is set for its slowest annual growth in a decade, the World Bank recently lowered its forecast for China’s 2012 economic growth to 8.2% from 8.4% previously. But in a sign that activity could rebound next year, the World Bank said it had raised its 2013 growth forecast for China to 8.6% from 8.3%.

The World Bank disclosed the revisions in its quarterly update of the Chinese economy and comes ahead of China’s official first-quarter growth report.

Analysts expect the world’s second-biggest economy to have grown by 8.3% between January and March, which would be its slowest annual pace in nearly three years.

Source: www.moneycontrol.com

WORLD BANK CUTS CHINA 2012 GROWTH FORECAST TO 8.2%

NEWS, VIEWS & ANALYSISNEWS, VIEWS & ANALYSIS NEWS, VIEWS & ANALYSISL A T E S T H A P P E N I N G S I N T H E W O R L D O F M A N U F A C T U R I N G

M A Y 2 0 1 2 | SEARCH - THE INDUSTRIAL SOURCEBOOK 43

“The burning issues facing the mining sector remain largely unchanged over time. But if we take into account the extent to which shifting social, economic & political trends affect the mining sector, companies will have to look beyond traditional planning,” said Kalpana Jain, Sr Director, Deloitte India.

The top 10 trends as identified by ‘Tracking the Trends 2012’ report are: The cost of doing business: With

commodity prices surging to all-time highs, accelerated production has become the mantra for most mining companies and costs are going up across the board. Capital expenditures are reaching a new peak. In some regions, investments in water, transportation and energy are expected to account for 82% of project spend. Indian companies need to explore ways to curtail energy costs and try to balance short-term requirements with long-term strategy, weighing the long timescales needed for mine development, against possible sharp downturns in prices and demand.

Commodity price chaos: There’s is no price stability without great transparency. Demand in China, India and Africa has witnessed a strong growth, showing little sign of relenting. But factors like decline in US domestic spending, a shaky European debt market, political instability and rising interest rates in Asia, have affected commodity prices. Currently, mining projects, both domestic & abroad, have become relatively viable due to improved commodity prices globally. However, given the global uncertainties, it is not easy to predict prices in near future. Hence, Indian companies need to adopt appropriate

hedging strategies and monitor cash needs closely.

The battle to keep profits: Government taxes target the mining sector. The bid to increase national revenues now extends beyond the introduction of new tax legislation. To maximise returns and manage political uncertainty, companies need to engage in financial modelling and engage at a political level to help influence government policies.

Restless stakeholders: To meet the demands of a broad stakeholder base, mining companies need to integrate risk-based corporate social responsibility (CSR) strategies and develop and track their key performance indicators with same diligence they use to track production. Until CSR is considered a direct business risk, mining companies might struggle to minimise the probability and financial impact of these risks.

Labour pains: Bridging the precarious talent gap. There are not enough people to power projected mining company growth. Companies need to adopt and apply strategies like workforce planning, introduction of industry-level cross-training and building a global culture in order to find willing employees.

Capital project quandaries: Project risk rises as the supply/demand gap widens. As commodity prices fluctuate and the gap between supply and demand widens, the number of capital projects across the globe is mounting in the mining sector. Mining companies need to now focus on managing risks that could interfere with their ability to meet steady-production objectives.

Non-traditional financing: New sources of funding require new levels

of knowledge. Despite cash liquidity, companies face difficulties in finding sufficient capital to fuel growth. The key to success in these efforts hinges on mining companies’ ability to build relationships to gain access in foreign markets, while gaining better insight into those regions. Though there are Indian players with cash reserves; they lack the expertise of operating mines in global regions. Hence, there is a need to collaborate with western companies who have expertise but lack cash.

The big get bigger: Risk multiplies as companies diversify. Dwindling access to deposits, deteriorating grades, spiking global demand and lofty commodity prices have heightened mining companies’ appetite for geographic and economic risk. Yet few companies possess the internal skills to grow their capital project portfolios aggressively or to operate in unfamiliar regions. For global growth, Indian companies need to focus on the quality of assets and reserves.

Volatility is the new stability: Plan for the unforeseeable. Although ‘black swan events’ are by definition rare, high impact and hard to predict, they are finding their way into corporate agendas. As Indian players expand globally, they need to consider mitigation plans for risk of events such as geopolitical movements to volatile weather patterns.

Legislative Olympics: Countries compete to become the world’s toughest regulators. Nations are increasingly focussing on the mining sector, heightening the need for mining companies to review their regulatory compliance procedures.

Source: Deloitte Touche Tohmatsu Ltd (DTTL)

MINING COMPANIES NEED TO TAKE THE UNCONVENTIONAL ROUTE TO ADDRESS CONVENTIONAL CHALLENGES

Issues facing the mining sector have reached a new level of extremity, forcing mining companies to incorporate more complex scenarios into their strategic planning, according to the Deloitte Touche Tohmatsu Ltd (DTTL) ‘Tracking the Trends 2012’ report. The report provides an analysis of the top 10 trends that are expected to impact the mining sector at an accelerated rate in 2012.


CUTTING-EDGE SOLUTIONS

he future belongs to electric vehicles experts are convinced. However, there are a few

challenges to overcome before strongly projecting electric cars as a viable option for combustion engines. One such challenge is power supply: batteries have to be safe, reliable and reasonably priced. In order to overcome these challenges, Fraunhofer scientists have come up with lithium batteries having improved properties, which include:Quick charging and dischargingIn case of strong winds or bright sunshine, renewable energy sources often deliver more power than the consumers’ need – so a way has to be found to store surplus energy. While lithium-ion batteries can store lots of energy, they also take a long time to charge. Supercapacitors, on the other hand, can quickly store energy, but their energy density is low.

Researchers at the Fraunhofer Institute for Silicate Research ISC in the Center for Applied Electrochemistry in Würzburg are now working on developing a battery that combines the benefits of lithium-ion batteries and supercapacitors. Depending on the requirements involved, scientists intend to produce energy-storage media that they can set either to the high energy density of a battery or to the high output density of a supercapacitor. For example, lithium-ion batteries could be charged many times faster than conventional batteries.Long service life through optimal coolingEven a few degrees’ temperature variation can make a huge difference; this law also applies to lithium batteries. Adding 10ºC cuts the energy-storage medium‘s life in half. So, an ingenious cooling system is indispensable. For

electric-car applications, researchers at the Fraunhofer Institute for Solar Energy Systems ISE in Freiburg have developed a well-cooled battery system. It consists of 12 flat lithium cells with a fluid-fed cooling plate on each side of each lithium cell. To get peak performance from the cooling plates, the researchers have simulated their form and tailored it to the geometry of the individual battery cells.Flexible and SwivellingLithium cells are usually rigid and immobile. Yet there is a demand for pliable cells in some applications, medicine being one example. Scientists at the Fraunhofer Institute for Silicon Technology ISIT in Itzehoe have

developed the first flexible lithium battery, which can bend and twist. But how did researchers accomplish this? “We work with very thin electrodes,” Dr Reinhard Mörtel, Scientist, ISIT, reveals.

In addition, the cathode, the separator and the anode all contain between 1% & 10% plastic as a bonding material. This material glues the individual particles to one another, thereby ensuring formation of the active layers. Researchers used laminable plastic to make the flexible cells. If the layers are warmed under slight contact pressure, they adhere very tightly to one another and will not separate even if the cell is twisted or bent. Pressure-resistant, even at 600 bar

For lithium batteries to supply electricity to underwater vehicles at great depths, they must be able to withstand enormous pressure. The researchers used two approaches to achieve pressure resistance: the cells they used are tension-resistant pouch cells. In pouch cells, the anode and cathode are wrapped inside a film from which all the air has been drawn out—not unlike vacuum-packed coffee.

The second approach involved the separator: the separator separates the anode and the cathode from one another to prevent short-circuiting. Usually, these separators are made of a thin layer of fibreglass that mechanical forces can easily destroy: the result is a short-circuit that can wipe out the entire battery. Researchers have now developed a ceramic-reinforced separator that offers considerably more safety. Another benefit is that the separator is rollable and can easily be commercially processed. As a result, a battery could be produced that withstands pressures of up to 600 bar (600 times normal atmospheric pressure). These cells also offer a very high energy density. Improved safety for lithium cellsSafety is an important criterion when it comes to batteries. With lithium batteries, the aim is to prevent short-circuiting. Another safety benefit: the ceramic structures are flame-proof, making it more difficult to ignite the electrolytes. Around 80% of all incidences of damage can be prevented through the use of a new electrolyte being developed by researchers at ISC. This is particularly important for lithium batteries with very high energy densities.

Source: Fraunhofer Research

LITHIUM BATTERY OFFERS THE HIGHEST ENERGY DENSITY

T

Cooling elements account for less than 20% of the cells’ total weight, thereby making the battery well-suited for lightweight construction in the automobile industry.

USPs

Whether it’s energy supply or electromobility – batteries are a key component. Promising developments in this area include lithium cells, which offer the highest energy density. These batteries are not just used in electric cars, but are

also in demand for the storage of wind and solar energy, for medical examinations or to propel deep-sea vehicles.


CUTTING-EDGE SOLUTIONS

n their efforts to render cars and trains more economical, manufacturers are trying to

find lighter materials to replace those currently used. But there is a problem: Lighter materials usually are not as tough as steel or aluminum, so they cannot simply be used in place of these metals. Rather, it is a question of manufacturers deciding which components can really afford to have weight shaved off and how to integrate them into the overall systems.

The creatorsWorking jointly with Bombardier GmbH, KraussMaffei Kunststofftechnik GmbH, Bayer MaterialScience AG, DECS GmbH, the DLR’s Institute for Vehicle Concepts, the University of Stuttgart and the Karlsruhe Institute for Technology, researchers at the Fraunhofer Institute for Chemical Technology ICT in Pfinztal have now developed a polyurethane-based sandwich material that is extremely resilient. Jan Kuppinger, Scientist, ICT, says, “To demonstrate the material, we manufactured a component that is subject to significant stresses and which has to fulfill a number of requirements—the diesel engine housing for a train.” Housing and its functions This housing is located beneath the

passenger compartment, i.e., between the car and the tracks. Not only does it shield the engine against flying stones and protect the environment from any oil that might escape, but in the event of a fire, it also stops the flames from spreading, thus meeting the flame retardant and fire safety standards for railway vehicles. “By using this new material, we can reduce the component’s weight by over 35% and cut costs by 30%,” Kuppinger adds.

Researchers opted for a sandwich construction to ensure component stability: Glass fibre reinforced polyurethane layers form the outer facings, while the core is made of paper honeycomb. Polyurethane is a bulk plastic combining two substances. Since it can be adapted to fulfill various requirements, it is referred to as a ‘customisable material’. In foamed form, it is soft and can be used as a material for mattresses; in compact form, it is strong and hard. Challenge encountered Researchers began by incorporating various additives into their polyurethane, altering it in such a way that it meets fire safety standards. Then, the partners optimised the standard manufacturing process and fibre spraying by developing a mixing chamber, which allows even more complex structures to be produced in any required size. The diesel engine housing they made is approximately 4.5 m long and more than 2 m wide.

“For the first time, it proved possible to use this process to manufacture such a large and complex component that also satisfies the structural requirements,” states Kuppinger. Previously, one problem that was encountered with

fibre spraying was that it was impossible to determine the precise thickness of the polyurethane top layers. Solutions arrived at However, researchers have found a way to do this. They use computer tomography to inspect the manufactured layers and then apply a specially adapted evaluation routine to establish their exact thickness. This information helps simulate the strength of the component as well as its ability to withstand stresses.

The scientists produced their diesel engine housing demonstrator as part of the PURtrain project, which is funded by the German Federal Ministry of Education and Research (BMBF). The demonstrator passed its first strength test – in which the scientists placed it in a test rig and then applied forces to it at various locations, measuring the extent to which it deformed.

In the next stage, researchers want to try the component in a proper field test. If that too proves successful, it will then be possible to use the material to make roof segments, side flaps and wind deflectors for the automobile and commercial vehicle industry, & to ramp up the manufacturing process to produce medium volumes of between 250 and 30,000 units.

Source: Fraunhofer ICT

RESEARCHERS DEVELOP MATERIAL TO BUILD LIGHTWEIGHT TRAINS

I

The polyurethane-based sandwich material is extremely resilient. It not only shields the engine against fl ying stones, but, in the event of a fi re, it also stops the fl ames from spreading. This material can reduce the component’s weight by over 35% and cut costs by 30%.

USP

Although this diesel engine housing for trains is made of a light polyurethane-based material, it is nonetheless capable of withstanding extreme stresses.

The less trains weigh, the more economical they are to run. A new material capable of withstanding even extreme stresses has now been developed. It is suitable for a variety of applications and it makes these components over

35% lighter than their steel and aluminum counterparts.

DR GUNTHER KEGEL

A fi rm believer in the power of automation, Dr Gunther Kegel, CEO, Pepperl+Fuchs GmbH, perceives automation to be a technology enabler. Dr Kegel says that the adoption rate and speed of introducing new technologies into the market is signifi cantly higher in India. During an exclusive interaction with Arindam Ghosh, Dr Kegel discusses the advancements that automation is set to bring into the manufacturing industry and charts out ambitious plans for the growing Indian market. Excerpts…

We believe in Technologyand Price leadership


GROWTH AND GRIP OF AUTOMATIONIn the 1970s, automation was considered a ‘job killer’.

However, this perception changed in the 1980s, when automation became more of an enabling technology, which provided the serving industry additional boost. Further, the arrival of such technologies led to miniaturisation; a classic example of this is the first cell phone. Today, with the progress in automation, cell phones have become sleeker and smaller than a cigarette box. However, the tremendous growth of the industry had an adverse impact on the envirionment in terms of pollution, which was an added incentive for the further growth and usage of automation technologies.

Automation also played a crucial role in issues pertaining to plant safety and plant utilisation. To make the plant reliable and available 24x7, or for an entire year, more automation-based sensors were implemented. This helped keep a check on unscheduled shutdown of the plant.

Automation also has an array of solutions to achieve energy efficiency. In fact, we can save as much as 40% of electrical energy in manufacturing plants by replacing existing old motors with new frequency converter-driven speed drives imbibed in automation architecture.

INDIAN MARKET FOR AUTOMATION SOLUTIONSIndia is a very challenging & competitive market, but, at the same time, it is a very promising one. In India there is a huge scope for automation, which can take care of mechanical manufacturing, environmental pollution along with

tackling safety concerns. So, whatever Europe and Germany could do in 50 years,


DR GUNTHER KEGEL

India now has to do it in 10 years. This is an El Dorado for automation technologies. Therefore, we strongly believe that India will give us the biggest growth rate year-on-year in the entire world market for automation. In addition, Indians are excellently educated and so, we have a lot of well qualified automation engineers, who are eager to implement new automation technologies. It is a perfect set up to have a very successful business here.

TECHNOLOGY TRANSFORMATION Introducing micro controllers in devices to make them intelligent was one of the most important technological transformations witnessed around the late 1980s-early 1990s. Today, we are still in a curve of adoption and so, people are in the phase of changing over from the analog interfacing to digital communication.

A very important feature of Indian customers is that they perceive new technology as something crucial; whereas, in other parts of the world, new technology is perceived as a threat. For instance, in Germany, we are apprehensive about new technologies and the negative impacts they have. India, on the other hand, has a positive attitude towards adopting new technologies. In fact, the adoption rate and speed of introducing new technologies into the market is significantly higher in Indian market.

FACTORS ENABLING DEVELOPMENT OF AUTOMATION SOLUTIONSWe have two major ways to take the development of automation solutions forward. Firstly, we strive to be the technology leader and secondly, it is our goal to not only offer the best quality standards, but also provide the best technical options to the market. Through these improvements and innovations, we aim to provide uniqueness & value to our customers. Quality has to be value for money.

We also try to maintain price

leadership. So, our investments are characterised by high-efficiency manufacturing; low-cost raw material; faster execution; higher reliability of manufacturing processes and setting up of manufacturing plants at very competitive parts of the world. All these factors help us maintain technology and price leadership in the market.

IMPORTANCE OF R&D R&D is the most challenging and most important facet of any automation company. We believe that R&D and quick time to market new ideas are the most crucial and competitive aspects of the company.

DEMAND TRENDS When it comes to technology, India is the only market I know of, which is keen to use and strongly imbibe the latest & best technology available in the market, but demand the lowest price for it. This contradiction is forcing companies like us to be front-runners in technology along with ensuring that our pricing is competitive. We believe that focussing on technology leadership and price leadership at the same time, can help us meet these demands of Indian customers.

SPECIFIC DEMANDS: PROCESS AND FACTORY AUTOMATIONI would say that historically, process automation has always had a much higher demand in India. The country has explored oil; it has explored gas before it really started to invest into light industry, machine building & car manufacturing, etc. This scenario has changed over the last 10 years. Meanwhile, process automation is more demanding from the view point of price, but the growth rates may not be at the same level as it is in the case of factory automation.

Moreover, various industries like machine building and renewable energy have become very active, which are actually generating splendid business opportunities for us. In the process

automation arena, we still have a solid but historical customer base, but in the factory automation space, we have new customers almost everyday.

What motivates youI like to work with people, share my thoughts and view points on the questions like how to improve products; how to do better service for our customers and how to meet their expectations. That’s an outstanding motivation in itself.

Your passionI am passionate about meeting my customers’ and my employees’ expectations. Customers are the most important, but my employees are also technically important.

Message to young professionalsHave patience. You have to learn in-depth to perform, before you actually get credited for it. There are excellently educated youngsters coming in from various universities, but honestly, they have no idea about how businesses really work. They have to learn to fly first before trying to jump out of the nest.

Challenging the extremities Once you have climbed one mountain, you can go in for the next one. Similarly, after you have executed the first challenge, you will automatically create the next challenge and execute it. It’s like when you go mountain climbing, it is never the goal to finally climb the mountain and then stop, it is climbing a mountain to see the next mountain, that you want to climb.

UP CLOSE & PERSONALUP CLOSE & PERSONAL

DR GUNTHER KEGEL

SEARCH - THE INDUSTRIAL SOURCEBOOK | M A Y 2 0 1 248

AWARENESS LEVEL AMONG SMEs If India has to move forward, there is no other alternative apart from implementing automation. People in the manufacturing industry are increasingly adopting automation technologies at enormous speed. I believe that those who do not implement automation systems will no longer be considered competitive in the market.

MEETING CUSTOMERS’ DEMANDS If you understand your customers’ expectations, then half of your goal is achieved. However, this is not an easy task, especially since our customers are majorly not automation specialists, but have expectations from their machine performance. So, the major challenge for us is to match customers’ expectations with the required specification through our specific automation systems. This is the secret to succeed in the automation industry.

MAJOR CHALLENGE FACED IN INDIAOne of the major challenges is definitely getting the right people on board and retaining them in the company for a long time. In India, we have a certain fluctuation ratio, which is higher than other countries. We would like to invite everybody to stay with the company for at least 10-15 years. In India, while on one hand we have to keep the talented people, on the other, the company may not be able to meet their expectations and needs. So, from time to time they make a move. This is a little different from other parts of the world, where the structure is more saturated. For instance, in Germany, the fluctuation ratio is 0.2%, which makes the attrition levels low. There is a need to ensure that your employees stay for long in your company rather than those of your competitors.

SUCCESS MANTRA Our customers have helped us find a

way to grow our business substantially. We have reached out to them in various regions including China and India, and provided them solutions according to their necessities and requirements. So, if you ask me who is responsible for the success of our company, I would say, it is definitely our customers.

INVESTMENT AND EXPANSION PLANS We have been investing 10% of our revenues into R&D annually. We are also investing heavily into infrastructure. In India, we have already inaugurated our new office infrastructure in Delhi and have established our new process automation headquarter in Bengaluru. We see ourselves growing substantially over the coming years. We are hopeful of more than doubling our business revenues in India in the next five years.

[email protected]

SEARCH May 2012 Ad Name: Peantair Pg No. 49

SEARCH May 2012 Ad Name: Renu Pg No. 50


OPINIONS & MORE

Opinions & More

‘Safety Should Be Made Part Of An Organisation’s Culture’Vipul Shah, President, CEO & Chairman, Dow Chemical International Pvt Ltd ..........................................52

SAFETY & SECURITY: Safety Comes First ......................................................................................54

INDUSTRIAL SAFETY & SECURITY: Innovative Technologies Popularise Safety Gears .................58

SAFETY & AUTOMATION: Achieving Zero-incident Workplace Through Automation ................60

SAFETY INCENTIVE MECHANISM: Securing Workplaces ............................................................64

SAFETY & SECURITY MARKET OVERVIEW: Capitalising On The Burgeoning Growth ................66

SECURITY IN DATA TRAFFIC: Building A Secure Firewall .............................................................70

OPINIONS & MORE


OUR TAKE ON WORLD-CLASS CHIEF EXECUTIVE SAFETY LEADERSHIP Safety leadership is more

than just a programme or an initiative. It is a mindset. At Dow, it is a way of life and all employees—from top executives to the newest hires—are expected to have an untiring obligation to safety excellence. It is an essential part of achieving our daily tasks and activities—on & off the job.

Dow’s ‘Drive to Zero’ safety initiative demonstrates its relentless pursuit to reach ‘zero’—zero injuries, zero incidents and zero excuses. Our constant emphasis is on, ‘safety first, pounds second’. Our safety leadership description has evolved and extended over the past few years. Our 2015 sustainability goals are representative of our intent to not only continue to improve our environmental, health and safety performance, but also to pace up with even more far-reaching, more unified & more innovative goals. This implies continuing to deepen the way we work with suppliers, joint venture partners, customers, governments and communities to understand & respond to shared challenges.

ESTABLISHING A SAFETY CULTURE IN THE ORGANISATIONWell, there are various factors that one has to consider while establishing a safety culture in the organisation. Some of them include: Make safety integral to the

company’s vision/values Define and advocate the strategic

direction for the safety function Establish company safety policies,

objectives, goals and requirements Lead, measure and assess progress

towards attaining the functional strategic objectives

Communicate safety risks associated with business, if any

Establish and confirm adherence to all compliances and go beyond.

Y

SAFETYSAFETY should should be made part of an be made part of an Organisation’s Organisation’s

CultureCultureDow is Dow is globally globally known for its stringent safety norms and this has been the known for its stringent safety norms and this has been the case & the practice at its Indian subsidiary as well. Living by the ultimate case & the practice at its Indian subsidiary as well. Living by the ultimate

vision of ‘Drive to Zero’ safety initiatives, vision of ‘Drive to Zero’ safety initiatives, Vipul ShahVipul Shah, President, CEO & , President, CEO & Chairman, Dow Chemical International Pvt Ltd, has been successful in Chairman, Dow Chemical International Pvt Ltd, has been successful in

imbibing the safety culture among each of its employees; and the results imbibing the safety culture among each of its employees; and the results are for everyone to see. During a brief interaction with are for everyone to see. During a brief interaction with Prerna SharmaPrerna Sharma, , he discusses his goals and elaborates on employee involvement to take he discusses his goals and elaborates on employee involvement to take

safety initiatives ahead. Excerpts…safety initiatives ahead. Excerpts…


OPINIONS & MORE

DOS & DON’TS FOR ENSURING SAFETY AT WORKPLACE… While establishing a safety culture in an organisation, one needs to ensure that it is woven into the core of the organisation and not added on as an afterthought. The safety measures must be ‘all inclusive’—employees, customers, government, products, operations, etc., and should have a goal, be sustainable and should evoke employee involvement. Only then will it be a successful and a well-rounded programme.

SAFETY MEASURES IMPLEMENTED AT YOUR ORGANISATION… Our offices and sites across the world strictly adhere to the Dow global safety standards. We also ensure that our operations, workplace and products are free from posing any significant risk to the health and safety of our employees, visitors, contractors, customers, carriers, distributors, neighbours, the general public and the environment.

We have a very robust global

environment, health & safety/sustainability (E&HS) function, which is accountable for providing an effective and efficient safety system. We meet or exceed all applicable laws & company standards, and are committed to continual improvement of our standards. We encourage and involve our employees in the evaluation and continuous improvement of plant, environment, health, safety and medical systems.

We strive to eliminate or reduce emissions, discharges and wastes from every stage of our operations and are committed to pollution prevention and continual improvement of our environmental performance. We are responsive to our employees, customers, neighbours and the government. We proactively share information concerning potential hazards resulting from our operations or our products. We have policies in place to implement these principles. All managers are responsible for implementing these policies and

procedures.

EDUCATING EMPLOYEES ON THE IMPORTANCE OF SAFETY As I mentioned earlier on, safety should be made part of an organisation’s culture and not looked at as a separate add on component. Our leadership plays a key role in ensuring that our commitment to safety is visible and that we remain vigilant. For example, when our leaders discuss their business’ quarterly performance with employees, EHS performance is discussed with the same priority as financial results.

YOUR ADVICE TO NEW GENX CEOs Lead from the top. Leadership plays a key role in cultural change. Also, ensure that safety involves everyone. Make safety a core value rather than an initiative, infuse it into your corporate strategy, integrate it across your company and continually measure progress.

[email protected]

SAFETY & SECURITY


ack then: During the 80s and 90s, India was at the receiving end of industrial hazards. The rather ‘infamous’ Bhopal

gas tragedy is still considered to be one of the worst industrial disasters in human history. Subsequently, there occurred the oleum gas leak at Shriram Industries in Delhi. A look at the times that followed made it clear that these ‘lessons’ taught us nothing as unsafe manufacturing facilities were still operational and major & minor mishaps continued to be a part of the industrial scenario. Incidents such as the gas leak in Mumbai and Durgapur, West Bengal, are proof of such negligence.Switch to the present: In due course of time, the manufacturing sector has become more cautious as it realises the importance of maintaining a safe & secure shop floor. But what could have prompted this change? Well, this change could be attributed to the change in the mindset...a change that could be substantiated from the fact that the industry, which never considered its workers to be an asset, is religiously implementing policies to safeguard their interests. Right from

making sure that employees have access to helmets and other basic safety gears, major players such as Tata, Godrej, Siemens, Larsen & Toubro (L&T) and General Motors (GM), among others, have laid out stringent safety measures to be followed at the manufacturing facility. Safety of employees has now become a core agenda for companies.

MAJOR PLAYERS KEEP IT SAFEIn almost every facility, companies are working towards offering their employees the most conducive working environment. One such company is Godrej, which has adopted certain measures to ensure the safety and security of not only their employees, but also their employees. Elaborating on the same, Hussain Shariyarr, Sr VP – Operations, Godrej Appliances, says, “We organise training programmes for employees at our Shirwal facility before they head to the shop floor. We also have a toolbox meeting wherein the employees interact with the department head for about 10 minutes at the start or end of a shift. Also, every week, we select a topic, like say, safety or environment, and talk about various initiatives, which have been taken or which should be taken and

how we could go about it.” Shariyarr also points out that safety has been a major concern for the company and the management will continue to follow the same. According to VN Desai, VP & Head – Modular Fabrication Facility (MFF), L&T, Hazira, “If a company wants to emerge at the international platform, it needs to follow global benchmarks. Keeping this in mind, we have demarcated three safety levels— people, process and equipment. To educate employees and bring the safety principle into practice, we have taken the services of DuPont. An expert team from DuPont was engaged for a period of almost one year, i.e., from March 2011–February 2012, to implement safety mechanisms in the division.”

Offering an in-depth perspective on the same, he adds, “To begin with, we conducted a three-day programme for the top management to spread awareness about safety-related mechanisms. This was followed by training the unit’s senior members. After that, the team identified nine critical risk areas, for each of which, safety standards were formulated. And the standards & procedures were developed by an internal team under the guidance of DuPont consultants.”

B NISHI RATH

The repercussions of the Bhopal gas tragedy that occurred 27 years ago are still clearly evident in and around Bhopal. So far, various unwanted incidents have occurred in manufacturing units across India. While some have come to light, many others remain unreported. But yes, based on our experience of industrial visits, it is clear that safety at Indian manufacturing facilities has come a long way. As India establishes itself as an economic superpower, it is still catching up with the rest of the world in terms of improving the working conditions of millions of its workers.

comesFirst

SAFETY & SECURITY


Although safety and security measures have made their way through the sector, industry giant, Siemens, believes that it has an entrepreneurial obligation to protect its employees, fixed & financial assets, know-how and other tangible & intangible assets over the long term (company security). They have a separate Corporate Security Department, which is responsible for meeting the above mission of the management. The company is actively spreading awareness through regular trainings, which are mandatory for all. Additionally, the company has a CCTV system in place to keep a check on every moment. Besides this, a crisis team and a mock drill is conducted at least once a year.

PUBLIC SECTOR FOLLOWS SUITMany would think that all these measures are only implemented by MNCs and private players. However, many public sector companies are also working towards creating a sound facility for their employees. One of them is Steel Authority of India Ltd (SAIL). The PSU has been routinely implementing measures to ensure that their organisation is a safe and healthy place to work. The steel major has a separate corporate unit, SAIL Safety Organisation (SSO), to cater to the same. This unit was set up in 1988 at Ranchi to create a safety culture, monitor safety activities of plants/units, evolve safety systems in operation & construction and keep abreast of the latest developments in the domain.

The organisation monitors and guides the safety, fire and occupational health activities undertaken at different plants/units/mines/stockyards. To accomplish these functions, SSO formulates and prepares appropriate safety policies, procedures, systems, action plans & guidelines. Later, it follows up their implementation, thereby helping in creating an accident-free work environment.

SAIL is not the only PSU, which is working towards ensuring safety.

Another major public entity, Oil & Natural Gas Corporation (ONGC) too does not believe in having complacency when it comes to adopting and practicing safe operating practices. The ‘Navratna’ company has regular safety classes and tests for its employees to ensure smooth & accident-free functioning.

SYSTEMATIC APPROACH TO SAFETYWhile almost every company is doing its best to implement the finest safety practices at shop floors, here are some crucial steps that can help check safety and security in order to avoid any major mishaps. These are based on the research we carried out by visiting some of the best facilities across various sectors, including power, engineering, automobile and consumer durables, among others. The steps include: Meetings: Organising weekly/monthly safety meetings to educate employees about the proper procedures to be followed at a manufacturing plant can be very helpful. Going further, each session can be dedicated to a particular topic. Also, first aid classes can help in spreading awareness about the steps that need to be taken in case of an accident or injury. Global majors, such as Eaton, strongly emphasise on organising regular meetings of employees and their respective supervisors to get the latest updates on the practices being followed or on whether there was any mishap. Organised shop floor: Keeping the work area clean and organised helps. A clutter-free work area will not only provide more space to work in, but will also help to reduce the number of accidents in the manufacturing facility. Various manufacturing units have a proper layout planned to not only sure seamless functioning, but also to keep the facility safe. Material handling companies, such as Voltas, Godrej, have a well laid out shop floor that clearly demarcates each & every job shop.Safety compliance officer: A safety manager/personnel, to constantly keep an eye on safety rules & regulations

being followed, helps to a great extent. The dedicated safety manager can interact with the employees, thereby making them understand the importance of following the safety measures. Industry giants, such as L&T and Tata, have got the best of security professionals to enhance safety levels in their organisations. Motivating employees by giving rewards: Nothing can be more motivating than a reward. Companies—whether big or small—can reward employees who take all the safety measures on the shop floor and follow the rules. This will not only motivate them to continue the same, but will also inspire other employees to follow suit. Companies, such as Klüber Lubrication India, have strong reward points in place for employees, who meet their safety targets.

SUPPORT FROM EMPLOYEES, A MUSTWhile the industry is taking every possible step to provide employees safe working conditions, employees, on their part, should also change their attitude and be aware & alert while working.

“After proper training and induction, many employees do not take their own safety seriously. They do not wear helmets or other safety gears provided to them, which might lead to accidents. This sort of carelessness never helps. So, we always urge the employees to cooperate with the organisation to create a safe and secure workplace for everyone,” says a security official of an automobile company.

Having said that, companies are undoubtedly doing their best to educate and create awareness among employees on various safety aspects. However, an integrated approach is what would actually help. As is rightly said: “A stitch in time saves nine”, it is now time for employees to stop and think about what is ultimately important and why safe workplaces are needed. This will definitely help the company to provide a much better and safer industrial culture.

INDUSTRIAL SAFETY & SECURITY


For any industry, employees are the most valuable assets and their safety & well-being is of paramount importance. Here, safety and security gears come into the picture. These not only provide protection from volatile and hazardous chemicals, but also keep employees safe from hostile temperatures at their workplace. Moreover, the latest technologies have helped in making these gears user-friendly.

he industrial safety and security market in India has dramatically changed in the last decade or so. Although the concept

of industrial safety was there since long, it is only in the last few years that the industry has implemented it

religiously. However, there is a long road to travel before it becomes

a statutory compulsion. Vinod Bamaniya, General Manager, Joseph Leslie & Co LLP says, “We are virtually at the

inception stage of accepting personal protection (PP) in

the industry. There are many sectors, which are still far away from using the right PPs for the right jobs. This includes sectors such as industrial construction. But

as the economy grows and become more globalised, this trend would also change and will lead to the growth

in the industrial safety business.”

Safety gears are always expected to

be robust and ready to combat tough env i ronments . Earlier these

gears were not very comfortable and stylish. However, a drastic change has taken place over the last few years. Bamaniya asserts, “The conventional eye wear are heavy

and old fashioned and so, the vision was also hampered. With a large portion of the manufacturing workforce coming under the 25-35 age group, there is a crying demand for better, attractive looking and comfortable products. Thus, many companies have focussed their product development strategy based on this concept. One company that I would like to highlight is UX, which has played a very significant role in changing the way eye protection is dealt with.” Companies have also come up with protective fabric that is smooth, trendy and looks vibrant with brilliant colours. Same is the case with safety boots, which are now available in different sizes and colours in trendy patterns. It could be said that safety gears, now a days, are no longer just for personal protection but also provide the much needed comfort with style.

LATEST PRODUCTS AND INNOVATIONS The latest technologies have supported the companies in launching hi-tech products in the market. Commenting on the technology development in safety gears, Bamaniya says, “Market dynamics have changed over the years in such a way that today, a buyer can approach one single organisation to source all the PPs required. Companies such as 3M have been hugely contributing in terms of new-age respiratory protection. They have introduced some of the latest technologies when it comes to disposable dust mask, in which antistatic fabric has now been used

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over the conventional PP disposable material.”

The latest developments in the safety sensor technology include those developed by Dräger and Honeywell. Bamaniya elaborates, “These companies have come up with excellent sensor technologies, which can be used for longer durations at reasonable price. Also, the conventional fabric used to only offer protection level up to five washing cycles to the end user. However, the technologically advanced garments are designed and manufactured so as to offer protection up to 50 washing cycles. New innovations have also been done in terms of fabric coating to improve the protection level of the material used in personal protection gear.”

Some of the other safety equipments in the innovative category include New-Tech™ ADC Plus auto-darkening reactive welding helmets. These helmets are lightweight and well balanced, and offer a wide viewing area, giving the welder a feeling of increased space awareness. The head gear can be set to fit each individual user for maximum comfort. The helmet shell is designed to provide maximum protection for the face, neck and ears, while providing a large area in front of the mouth to ensure a good flow of air and low levels of carbon dioxide. Powered by solar cells, New-Tech ADC Plus helmets feature ‘Angular Dependence Compensation’ (ADC) technology that ensures a solid shade level covers the full width and height of the LCD screen, even when viewing the lens at an angle.

A range of stylish safety glasses (used for drilling, chipping and metalworking) are also available in the market. These glasses are stylish, soft, and have a lightweight wraparound, including a neck cord. They are extremely flexible & durable and are available in multiple different lens configurations providing protection against dangerous UV radiation. Another innovative safety equipment is the 3M™ Sound Examiner SE-

400 Series Sound Level Meter, which works aptly for places that have highly variable noise levels. The easy-to-use SE-400 series sound level meters help measures average (LEQ/LAVG), maximum, minimum, and peak sound pressure levels.

In the fire safety gear category, Lion Apparel has introduced ProtexMaX, a product that combines new technologies in fabric to achieve extremely high mechanical & thermal properties and a waterproof, breathable, moisture barrier. The garment also uses a new lining system, which is based on wicking technology to remove moisture and heat from the body. This gear also provides much greater range of arm movement without the jacket riding up.

Recently, Fhoss Technology has also come up with a new illuminated clothing system that helps equipment operators to locate other workers even in poorly lit conditions. The company has combined the traditional reflective tape with an electroluminescent core that sits behind the semi-transparent tape and actively emits light.

In the gas protection category, petroleum companies were always on the lookout for equipment that could help detect gas leakages. Maclean Pagar, Senior Manager – Gas Detection System, Joseph Leslie Dräger, says, “In the gas protection equipment, technologies like infrared for the detection of hydrocarbon gases found in refineries & petrochemicals industry; and catalytic sensors for detection of hydrogen gas & hydrocarbon have come up. We have also indigenised certain products considering the need for low cost products from the government.”

SECURITY ISSUES SIMPLIFIEDWhile these developments have come up on the safety front, many new technologies have simplified security issues as well. Sreenivas, Project Coordinator, Security Vision, articulates, “As far as technological

advancement in security is concerned, the whole process is migrating towards IP-related activity. In the Indian market, both conventional as well as IP based CCTV systems have are in equal demand. Also, access level authentications have come up majorly in manufacturing units and critical installations like BARC.”

He further adds, “At present, MNCs are foraying into the Indian market with many branches. The employee movement within these facilities are controlled by access control. This is significant for the management to have a grip on everyone’s movement within their offices as well as the manufacturing units.”

Discussing about other security related technologies, Sreenivas says, “New technologies like thermal imaging camera that can look into complete darkness have come into the market to counter serious security threats. Certain biometric based technologies, which uses biological traits to identify the person, have also come up.” With so many developments and innovations present to ensure safety & security, the consideration for human comfort cannot be left out.

The next upgrade to these technologies is expected in the form of wireless technology, which will revamp the way safety equipment and security devices are used today. Bamaniya avers, “Home grown companies like us have been trying to develop our own technology that can cater to the Indian industry. This can be sustained, both in terms of price and application-wise. We have also built manufacturing facilities for disposable dust masks since in the next 10 years, industrial safety business in India will show an upward movement in tune with the industrial developments. With this, we will see many new age technologies coming into the Indian market that will find suitability as well as economies of scale.”

[email protected]

SAFETY & AUTOMATION


Manufacturers around the globe are proving that protecting workers on the plant fl oor can also help improve effi ciency, productivity, and business performance, ultimately helping create differentiation in the marketplace. Their top-down management commitment includes adopting global safety standards, implementing safety automation technologies, innovative design approaches, and other initiatives to deliver signifi cant business and economic value. Here, we have discussed some of the widely used automated technologies and what led to their use on the shop fl oor…

ver recent decades, the industry has majorly overhauled its productivity and the advent of automation technology.

The use of modern standard solutions allows automation systems to be efficiently connected and their data used for comprehensive analysis purposes. However, the improvements gained in terms of accessibility, efficiency and productivity must be accompanied by a high-level of protection.

In the last few years, number of accidents in the industrial space has raised public and regulatory concerns. Various accidents occur mainly during maintenance, troubleshooting and repairing and, when the machine starts-up unexpectedly. These conditions of man-machine interface need better understanding and development of methods, and tools to control them.

REASONS FOR AUTOMATION ADOPTIONNew global standards, technological innovations and well-defined risk-management tactics in automation have helped minimise the safety issues. When deployed properly with a holistic approach, safety automation systems

can provide a safer workplace, boost productivity and reduce environmental impact. As safety automation systems are being integrated with the standard plant-automation system, end users and machine builders can reap the rewards of having a single platform that meets safety standards and efficiently operates the plant. This approach will, in fact help in minimising the hazards based on detailed risk assessments, in the early stages of projects. In addition, it allows the designing capabilities for improved diagnostics, maintenance procedures, and quick recovery processes.

MINIMISING IMPACT OF INCIDENTSIt would be correct to say that automation technology has come at the right time since manufacturers are keen to reduce the time taken to complete a task while still managing safety and security issues. During the last decade, Abnormal Situation Management Consortium and its member companies have invested ample time to develop guidelines, principles, and best practices in designing alarms, displays, and general operating systems. All these activities have been aimed at reducing the frequency and impact of accidents.

“The ASM Consortium recently conducted a study at a chemical plant and reported around 35% improvement in recognising process deviations before an alarm; 25% increase in likelihood of successful intervention and 35-48% improvement in operator response time to deviations,” says Pankaj Deshmukh, Business Development Manager – Advanced Solutions, Honeywell Process Solutions India.

He further adds that using a training simulation, operators who worked on a system built as per the ASM guidelines were compared against those, who used an earlier vintage control system. Operators were subjected to similar scenarios, using a classic ‘design of experiments’. The final results indicated better recognition of abnormal situations and/or events while using the ASM-styled system.

Deshmukh quotes an example, “Some time back, a refinery asked for a solution to protect and comply with a variety of strict safety standards and improve safety performance of its new heater system in the refinery crude unit. The choice was clear given that the Safety Manager meets strict burner management compliance standards

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of the National Fire and Prevention Association (NFPA) for fire prevention and public safety.”

The safety PLCs, complying with latest safety standards including IEC 61508, ISA S84.01, DIN V 19250, UL, FM, ATEX for emergency shutdown, provide essential component of the protection strategy. Together with control systems and the layers of protection that are inherent in terms of alarming, boundary management and procedural operations safety systems provide the basis for critical control and process safety.

THE POPULAR TECHNOLOGIESAmong various automated machines and technologies that are being used by the industry, the one that has gained momentum is the machine, which tracks an employee in case of an accident. If an unfortunate incident takes place, the immediate need is to locate where all the workers are placed. Here, the wireless personnel location awareness system plays a significant role as it is being designed to improve the workers’ safety. Many MNCs are seriously contemplating installing this system at the shop floors.

Also known as real-time location systems (RTLS), this system typically relies upon active radio frequency identification (RFID) tag transponders worn by workers, contractors and visitors. The locations of these people can then be determined in real time, thanks to the RF sensors mounted within a plant or industrial complex that receive signals from the tags. The associated software calculates the locations and converts the data for mapping, report generation and other functions. It should be noted here that the tags and sensors must be certified intrinsically safe while using in hazardous, explosive environments.

Many companies are also opting for the Global Positioning System (GPS) satellite technology for outdoor applications, covering large areas beyond pre-assigned zones.

ACHIEVING PROCESS SAFETYAutomation is also being used frequently to attain the process safety. As of now, the industry boasts of many safety solutions though they are point solutions—filling a void in one layer or solving only one problem. As a result many new technologies have been introduced, which work as a complete package.

Around the world, virtually every site has defined and established these limits as a result of OSHA (Occupational Safety & Health Administration) recommendations. However, most of them have done this in a standalone basis; capturing and documenting the information in word documents, excel spreadsheets or other databases. As a result, they are not able to operate within the design envelope regularly.

“Automation solutions can help by hosting these limits in real time and on-line systems and by ensuring that alarm system in the control panel is co-ordinated with these limits. And automation solutions can provide systems to continuously monitor the process for deviations from these established limits,” says Deshmukh.

It will also provide the operator, a real-time view for supporting documentation, as and when necessary. The appropriate application will also notify the operator when a deviation occurs, enable operator comments on deviations and report deviations to be collected, and reported to management. This system will help in continuous improvement and specific problem solving.

The ARC studies have indicated that incidents and losses in the process industries are often not from the assets that we tend to focus automation efforts on. “Similarly, automation efforts are often focussed in the control room leaving the outside operator or field operator without the benefits of this technology. This scenario is changing with the introduction of mobile computing technologies.

ARC reports that in Process Field

Operations safety and avoiding human errors ranked as one of the most important factors in justifying the use of mobile computing technologies,” Deshmukh says.

By automating inspection processes, schedules and enforcement of business rules in a single system, management will have assurance that regulatory compliances are being completed. And the exchange of information means that informed decision making is taking place. A process safety strategy will need to include the aggregation and consolidation of task management, standard operating procedures, operator rounds, equipment & electrical inspections, safety inspections, and standardised work processes, implemented in a common mobile workforce. This must be able to provide the necessary personnel with warnings and/or notifications, if the facility is in danger of missing any regulatory compliance—by facility, asset or resource.

AUTOMATION: WORKING ITS WAY TO INDIAN SHOP FLOORSIndustry sources assert that almost every facility in India has some or the other kind of automated machines/ technology today, still it’s a long way before automation solutions feature regularly at the Indian facilities. What is actually required in India is automation, coupled with good training techniques, effective integration of machine safeguarding and controls that not only reduces the risk to the operators, but also enhances their awareness of danger zones. It must also provide a safe and productive operating environment.

With the growing competition, India would see a lot many automated facilities in future. To be at par with the global counterparts, many companies are already adopting hi-tech automation solutions in their facilities with an aim to get speedy & accurate work and better safety of the employees.

[email protected]

SAFETY INCENTIVE MECHANISM


Surveys reveal that one among six workers in the country is injured at the workplace. This is because of the lack Surveys reveal that one among six workers in the country is injured at the workplace. This is because of the lack of proper awareness, personal safety equipment and lack of incentives based on safety and security measures.of proper awareness, personal safety equipment and lack of incentives based on safety and security measures.Implementing incentive-based safety and security measures at a workplace are crucial as they prevent incidents of Implementing incentive-based safety and security measures at a workplace are crucial as they prevent incidents of injury while enhancing productivity. injury while enhancing productivity.

afety and health of workers have a positive impact on the productivity and overall economic & social development. Hence,

for a company, high safety and health standards at work are as important as a good business. Garry Richards, in his book, ‘Safety vs. Challenge’, explains, “Safety is understanding; it is an attitude of mind – it is not necessarily simply following of rules or directions.” It is something, which ensures that you work without fear, thereby increasing the overall productivity of the industry. The idea later enabled the inclusion of incentive methodologies as part of business strategies to ensure safety and security of employees. The industry has safety and security mechanisms in place; and, it is getting simpler, but

costlier, with technology advancements. Companies follow safety and security norms made by the Government of India, but ongoing accidents at the workplace raise questions about whether the government’s safety norms are effective enough.

INCENTIVES, SAFETY & SECURITYShould an employee be paid an incentive for working safely? How does the incentive mechanism work for employees’ safety and security?

Incentives are broadly categorised into cost, performance or technical, and schedule & delivery. Performance or technical incentive measures include quality and safety. The following are three methods of incentives, which are popular among industries: Reactive: As the name suggests,

reactive responds to those events, which have already occured.

Proactive: The proactive method actively tries to identify safety risks by analysing an organisation’s activities.

Predictive: This method captures system performance as it happens in real-time normal operations to identify potential future problems. Discussing the added benefits of

the incentive mechanism, Ravindra Kishore Sinha, Executive Chairman, International Institute of Security and Safety Management & Chairman & MD, Security and Intelligence Services India Ltd, asserts, “By giving incentives, the company is not wasting or investing money; rather, it is saving money. Who can forget the Bhopal gas tragedy? It happened because the

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management team did not allow the shutting down of the factory for 24 hours for maintenance, which was undone for a few weeks.”

Different sectors need different levels of security and safety standards.For instance, a chemical factory, which produces toxic compounds; lead factory and tubelight factory are among those which seek high levels of attention.However, irrespective of all the efforts made by a company, safety and security of an employee ultimately depends on the employee’s levels of consciousness. The incentive mechanism thus works towards enhancing the self-consciousness of employees towards safety, health and security.

CONVINCING OR CHIASMIC FACTORS?In such a scenario, how should the industry establish norms and modes of incentives? For big companies, it is easy to form an executive team to look into all these matters. However, for SMEs, most of which are having irreversible methodology in profit making, a little addition to their cost may lead to losses. According to Sinha, “By doing so, Indian SMEs are spending pounds to save pennies.”

Factors, which must be included while determining performance or technical incentives include:Job based: Different jobs need different levels of attention. So, when setting an incentive for a particular job, one needs to measure the danger level in a workplace, according to which a standard scale can be defined. Counting injuries: Incentives can be given based on performances like getting a result for a certain number of days without any injury.Team based or individual oriented:

Incentives to be given in this regard should be on a team-based or individual-based performance. Giving individual-based incentives will bring negative competency within the team, which may cause more damage. Framing timeline: The management should set a realistic time frame for

receiving incentives. Because of these chiasmic factors, an official from Mahindra and Mahindra points out, “We do not give safety and security-based incentives. For that, we have a safety & security cell headed by our Chairman. The cell trains and educates people in this regard. If any person gets injured at the workplace, we make a film on the incident showing what the causes were behind the accident.”

NATURE OF INCENTIVESIncentives can be in various forms. It could be in the form of cash (the idea of consolation prize can also be explored). In Europe, few companies promote ‘alcohol-packed’ parties as incentives. The nature of incentives are representative of the creative management of the company. For instance, many companies distribute

T-shirts with their company logo, as surprise incentives. Apple has its own way. When the MAC team created their much-awaited MAC computers by working 12–18 hours daily, Steve Jobs felt that there must a specific surprise incentive for the team. He told all the members of the team to put their signatures on the motherboard of the computer. Although these signatures are not visible, it made them proud. Reminiscing the incident, Jay Elliott, Former VP, Apple, wrote, “Whenever I see people using MAC, I feel proud that my name is written inside the computer.”

GOVERNMENT & OTHER INITIATIVESEmployees’ safety has been covered in ‘The Factory Act, 1948’. More or less, the same Act is regarded as the essential norm in industries. Further

amendments were made in 1987 (Act 20 of 1987) under the Factories Amendment Act, 1987. The Mines Act, 1952, Dock Workers (Safety, Health & Welfare) Act, 1986 were the few other Acts, which were passed in this context. ISO OHSAS 18001 covers Occupational Health & Safety (OHS) standards. Companies that build and maintain an OHS programme in compliance with this voluntary standard will have an easier onus to successfully prove due diligence in defence, if they were indicted under the Factory Act. This requirement to comply is also reinforced by various other incentives, which include improvement of the mitigation and management of the health and safety risk to workers, showing good corporate governance, reduction of operational risk, mitigation of legal and criminal

liability risk and so on. Sinha says, “As far as the question of government’s commitment is concerned, it has achieved a landmark by passing Private Security Agencies (Regulation) Act 2005 (PSARA 2005)”.

INDIA IS SHININGEven though India is still at a nascent stage in comparison to the US and the UK securities, Sinha believes that “India is shining”. He adds that compared to those countries whose development rate in the field of safety and security are 2–5%; India’s development rate (which is around 25%) is quite promising. Companies are keen to elevate their standards as per the global standards in order to maintain sustainability and growth.

[email protected]

By giving incentives, the company is not wasting or investing money; rather, it is saving money. Who can forget the Bhopal gas tragedy? It happened because the management team did not allow the shutting down of the factory for 24 hours for maintenance, which was undone for a few weeks.

Ravindra Kishore Sinha, Executive Chairman, International Institute of Security and Safety Management & Chairman & MD, Security and Intelligence Services India Ltd

SAFETY & SECURITY MARKET OVERVIEW


Over the last fi ve years, the safety and security systems market has been growing at over 35% annually. This market is predicted to grow rapidly till 2020. Given the enormous potential India offers for such critical solutions, companies today are making all possible efforts to keep up with customers’ expectations by adhering to stringent quality & safety norms. Here’s a glimpse into the lucrative business of safety & security systems, which is bound to grow in the years to come...

A ARINDAM GHOSH

ccording to the International Labour Organization (ILO), an estimated 1.2 million workers lose their lives

annually across the world in work-related accidents and diseases. Each year, there are around 250 million occupational accidents and 160 million work-related diseases—the economic loss arising from which is estimated at a whopping 4% of the world GNP. Consequently, it has been recognised globally that implementing effective safety and health practices in organisations have

positive impacts on the company’s productivity. This, in turn,

uplifts that particular company economically and socially. It not only averts economic costs incurred during a mishap at the workplace, but also enhances workers’ productivity levels.

Commenting on the importance of safety, Prateek Verma, Sales Director, Vantage Integrated Security Solutions, says, “Developing a strong culture of safety and a healthy work environment have become integral aspects of the work culture. This trend has been witnessed for over a decade now. The government, as well as the private sector, are taking proactive steps to ensure safety and are working towards creating a healthy work environment by installing a suitable security system

with access control and CCTV surveillance within their units.”

KEY CONSIDERATIONS IN DEVELOPING SAFETY SYSTEMS Recently speaking at a conference on ‘Safety,’ Union Minister for Labour and Employment Mallikarjun Kharge said, “Manufacturers need to initiate continual improvement programmes aimed at achieving zero accidents in their organisations and thus improve their productivity.”

Given the fact that both the

government and the industry are strongly focussed on the

implementation of safety and security systems,

c o m p a n i e s a r e developing products,

which are not only superior quality wise, but also have strong safety values. On this note, Verma informs,

“Most of our products are CE &

FCC certified. We follow strict quality

compliances to ensure that the quality of our products is

not compromised on in any way.” Some of the other important norms followed in the manufacturing of various security systems include implementation of quality motion sensors. This is one of the core components of the security alarm and safety system. The passive infrared (PIR) motion sensors are widely deployed in security systems that require motion detection. Higher the quality of sensors, the more efficiently would it be able to detect any movement and usage of standardised microprocessors for metal detector solutions.

Some of the other specific protection systems, such as guard patrol systems, are made using the moulded rubber shell and are designed with a metal body, which helps in securing the data stored and protecting it from any damage. Wireless smoke detection systems consist of a central monitoring console and a series of remote sensing smoke detectors. The smoke detectors use state-of-the-art remote sensing technology, which detects smoke and raises a clearly audible fire alarm.

Also, many companies make it mandatory for workers to wear specific protective clothing when working

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SAFETY & SECURITY MARKET OVERVIEW

in factories. They include specially designed suits that offer protection from fire and extreme heat in the factory, especially for those who work in metal industries.

GROWING MARKET FOR CCTVs According to industry body, ASSOCHAM, the video surveillance and closed circuit television (CCTV) camera market in India is likely to reach `2,200 crore by 2015. The Indian CCTV camera market is currently poised at about `1,000 crore and accounts for over 40% of the `2,400 crore worth total electronic security market in India. “Rapid economic growth & rising industrial activities amid security threats and fear of potential terrorist attacks have fuelled the demand for CCTV cameras. Evidently, government authorities and even private sector are heavily investing money in installing CCTVs to secure their offices and public places across the country,” says DS Rawat, Secretary General, ASSOCHAM.

Globally, the CCTV and video surveillance market is growing at a CAGR of about 25% and is currently poised at about ̀ 80,000 crore. It is likely to cross the `1.5 lakh crore mark by 2015, according to the ASSOCHAM study. Asia accounts for nearly 35% of the global CCTV market with a share of over `27,000 crore. Commenting on the prospects of the Indian market for protection and safety solutions, Verma informs, “India has a huge market for these products. The annual growth rate in our industry over the last five years has been over 35%; and the same is predicted to grow at a fast rate till 2020. Since 2010 onwards, India has been the fastest growing market for security products.”

CASE IN POINTIn terms of implementing effective health and safety standards, Lafarge India has undertaken a series of initiatives at its Sonadih Cement Plant. These include:

The plant follows practices such as working at height (WAH); personal protective equipment (PPE) usage; energy isolation; lock out, tag out, try out (LOTOTO) and transportation safety.

Every June, they celebrate health & safety month across all Lafarge sites globally. Due to its stringent policies

and procedures, Lafarge India has been able to clock 42 million man hours without any major incident or accident. Recognising the efforts taken during the implementation of a safe and secure healthy environment, the company has been awarded the first FICCI Safety Excellence Award for Manufacturing.

However, Shubhangi Kitchloo, Executive Assistant – International Centre for Advancement of Manufacturing Technology, UNIDO,

says, “In India, there are very high variations between the factories.” On the basis of capital, she categorises the industry into two sections—high end and lower end. She says, “There is a strong focus on safety for all the high end industries. They have strong guidelines in place towards ensuring maximum safety for workers. They regularly conduct training programmes for workers, which makes them feel more secure at their workplace. Moreover, implementing such programmes makes workers more efficient.” In the case of small-scale industries, following such strong safety standards may not always be possible.

REGULATORY FRAMEWORK IS A MUSTGiven the fact that more than 90% of workers are from the unorganised

sector, a lot of initiatives aimed at improving productivity as well as strengthening competitiveness of workers have been undertaken by the government. These include: The establishment of ITIs and skill

development centres. The government has set a target of making 500 million persons skilled by 2022.

Launching Rashtriya Swasthya Bima Yojana—a smart card-based cashless health insurance cover to below poverty level (BPL) family of five in the unorganised sector. Around 93 lakh smart cards have been issued under the scheme. However, if the government can

introduce a regulatory framework towards making the adoption of good PPE and follow a basic set of safety practices as part of the mandatory practices to be followed by workers,

especially for those who are working in factories, it will come as a huge boost towards implementing a safety and healthy work environment for workers. “I believe that we should have a legislation making it compulsory to have a basic surveillance and security setup for all organisations, whether they are private or public. That will be the most effective way to get people to have at least a basic level of security,” Verma concludes.

If all these measures are taken in their entirety, we will soon be able to witness an injury & accident-free environ across industries and across the country. If this dream materalises, India will be one step closer to achieving its ambitious target of 25% by 2025.

[email protected]

There is a strong focus on safety for all the high end industries. They have strong guidelines in place towards ensuring maximum safety for workers. They regularly conduct training programmes for workers, which makes them feel more secure at their workplace. Moreover, implementing such programmes makes workers more effi cient.

Shubhangi Kitchloo, Executive Assistant – International Centre for Advancement of Manufacturing Technology, UNIDO


hile IT security in office networks has long since become standard, the situation in production is different. Established

security concepts, such as office firewalls, are not that easy to apply to automation networks. These networks play by their own rules. For example, the protection of automation networks must not conflict with requirements, such as performance or usability. Additional costs also play an important role. How can potential risks be minimised using adequate yet affordable security in industrial automation? There is no easy answer, since every plant has different limiting conditions, risks and protection goals. However, there are proven approaches with a manageable number of key components with which an efficient security concept can be developed.

SECURITY AWARENESS AS THE BASISIrrespective of how good a security concept is, it is of no use if all the

employees do not have a basic understanding of the issue. A promising security management solution can only be implemented with full awareness of all parties, assigning responsibilities, defining processes & measures and developing corresponding emergency plans.

The preconditions for such a solution are a sound risk analysis and the determination of the resulting protection goals. Otherwise, the company is in jeopardy of taking unsuitable measures that are too expensive, ineffective or may not be able to detect and correct weak points.

If there exists a connection between the corporate IT network and the industrial IT network, it is imperative that all interfaces be protected. First, the permissible types of access from the corporate network into the industrial network need to be defined, together with the kinds of data that may be transferred in the opposite direction. These definitions are then translated

into regulations & access rights and are implemented via corresponding technical measures. Network intrusion detection systems and firewalls that detect access attempts in the entire network and regulate the data traffic in both directions take first priority in this process. It is also possible to set up a demilitarised zone in which both the networks can exchange data without being directly linked.

PROTECTING CONTROL SYSTEMSJust like PC systems in offices, PCs and PC-based control systems in the industrial network need to be protected against malware. Also, possible gaps in the operating system or the user software need to be closed. Many of the protective systems that have been proven in the office environment can be used for this purpose, for example, regularly updated virus scan software. However, these do not detect all viruses and are sometimes completely powerless against new viruses. Also,

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Ethernet-based communication is becoming more and more important in the production area. In addition to the now Ethernet-based communication is becoming more and more important in the production area. In addition to the now possible use of open and standardised IT technologies, the main advantage is the continuous networking it provides. possible use of open and standardised IT technologies, the main advantage is the continuous networking it provides. However, the vulnerability of these networks, and thus the risk of serious economic loss, is increasing. This is due However, the vulnerability of these networks, and thus the risk of serious economic loss, is increasing. This is due to the fact that since standardisation, the number of users having access to critical and formerly isolated areas is to the fact that since standardisation, the number of users having access to critical and formerly isolated areas is constantly growing. IT security therefore plays a decisive role.constantly growing. IT security therefore plays a decisive role.

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timely updates can be a problem in the automation environment, for example, if no maintenance windows are available.

A good alternative to antivirus software is whitelisting software. This type of software uses positive lists (white lists), through which a user can determine which processes or programmes may run on a computer. If a user or a piece of malware then tries to install a new programme, it may be possible to install it; however, the programme cannot be started and therefore, cannot cause any damage.

It is more difficult to protect PLCs and HMI systems that either do not use a commercial operating system at all or use an older version. The use of third-party security software is not possible in this situation. In addition, access to the system functions of the devices is often not possible or limited. Here, the manufacturers of automation hardware are called upon to implement corresponding security mechanisms and make setting options available to the user.

Another important point is the fundamental robustness of the systems regarding the influence of faulty data telegrams and larger, unwanted data streams. The manufacturers must ensure that the devices are tested for any weak points and ‘hardened’ accordingly with certain measures. As with PC-based systems, it should be possible to deactivate services, protocols or unused interfaces in PLC and HMI systems.

NETWORK SECURITYMost automation devices today do not have sufficient security functions of their own to be able to protect themselves. Due to their long service lives, this is not going to change any time soon. Yet, these devices need to be protected. The cell protection concept has proven effective as a solution to this dilemma.

The idea is simple: specially hardened network components (security appliances or security

modules) that have security functions such as firewalls and virtual private networks (VPNs) are used. These security appliances are connected upstream from the automation devices and form the only access point to these devices, thus protecting them.

In this way, automation cells are formed and the network is segmented from a security viewpoint at the same time. Using the firewall of the security appliance, the data traffic from and to the cell can be controlled and thus unauthorised access can be prevented.

The security appliances can also set up secure VPN channels with each other, so that the communication between the cells can be encrypted and safely authenticated. In this way, data transmission can be protected against manipulation and espionage.

The advantages are obvious: One security appliance can protect several other devices, which imply that these functions do not need to be installed and administered in every device. Within the cell, real-time communication remains unaffected by performance-intensive security functions, and yet, access to the cell is protected. Devices that cannot be protected by the cell protection concept must protect themselves. In this case, the communication participants must authenticate themselves directly on the device. Application-specific access rights can be realised using several protection steps, for example, through different passwords per protection step.

PROTECTION AGAINST ACCESSAll access to a network must be monitored if unauthorised access is to be prevented. In addition to secure remote maintenance access, the ports of network switches and routers need to be considered. The ports of the network components must therefore have at least corresponding access lists that determine which devices may connect to which ports.

Many network switches support the IEEE 802.1x standard for this. The authentication of participants connecting to a port is performed by an authentication server, which is queried accordingly by the network switch. Additional security is achieved by using only hardened products, if possible. It implies that the products have been inspected by the manufacturer for any weak points during their development, and that detected weak points have been eliminated so that they cannot be exploited by hackers or malware.

FOR SECURE AUTOMATION Even though the threats to automation networks have increased and become more complex, a well thought out security concept and application-specific measures can allow automation networks to be operated even today with a reasonable degree of security at an economically justifiable cost. Naturally, the operators are responsible for the secure operation.

In any case, the effective implementation of a functioning security concept requires the cooperation of the users and the operators, but also of the manufacturers of automation technology. In addition, standardisation bodies need to draw up corresponding guidelines and wherever possible show standardised processes or measures.

The article is an excerpt from Siemens’

in-house magazine – Advance.

Franz Köbinger, System Manager – Security,

Siemens

E-mail: [email protected]

Security management Protection of the interfaces

between corporate and installation networks

Protection of PC-based systems in the installation network

Protection of the control level Network security

5 STEPS TO A MORE SECURE INSTALLATION NETWORK


INDUSTRY DYNAMICS

INDUSTRY DYNAMICS: Critical Nerve Centre For Manufacturing ...............................................74

WIRES & CABLES OPPORTUNITIES: Transmitting Waves Of Growth .........................................76

WIRES AND CABLES OUTLOOK : Are We Heading Towards A Wireless Future? ......................80

POWER CABLES: Maintenance Is Better Than Repair ....................................................................84

INDUSTRY DYNAMICS


Growing at the rate of about 15–18% per annum, wires and cables has, today, become one of the fastest expanding industries in India. The expansion of the industry is a result of the government’s increasing focus to improve the power scenario as well as the overall infrastructure development in the country. The future looks much brighter for the industry, as the country will be investing US$1 trillion in infrastructure development, while it targets to generate 1,00,000 MW of power.

ARINDAM GHOSH

Critical Nerve CentreFor Manufacturing

wing to various initiatives taken by both the g o v e r n m e n t and the private

sector, the industry for wires and cables is booming in India. Initiatives such as introducing policy reforms and making huge investments towards developing & expanding the Indian power sector—which is the largest consumer of wires and cables in the country—have certainly contributed immensely towards the growth of this industry.

Apart from these, key initiatives taken by India in terms of implementing state-of-the-art and sustainable infrastructure in the country have led to the development of various other industries such as railways, telecom, etc., which, in turn, have offered a boost to the development of the Indian wires and cables industry.

According to Rakesh Goyal, Director, Chetan Cabletronics, the Indian cables industry is growing at the rate of about 15–18% annually. This growth rate can be bettered if major challenges such as rising raw material prices, availability of skilled manpower and lack of good R&D facilities are tackled at the earliest.

IMPORTANCE OF WIRES AND CABLESOver the decades, the development

of infrastructure has gained the government’s undivided

attention. Consequently, the government has increased its infrastructure spend as a percentage of the country’s GDP from 5.15% during the 10th Five Year Plan (2002–07) to 7.55% during the 11th Five Year Plan (2007–12). This is expected to increase to over 9% during the 12th Five Year Plan (2012–17). Power

Rise in infrastructure development has created

a huge demand for wires and cables considering that

improving the power scenario in the country is a crucial enabler to support the development of infrastructure in India. The power sector has the highest demand for wires and cables. Here’s why… For a country, like India, the transmission and distribution (T&D) losses in power are very high. Presently, India faces about 30% T&D losses. As per government estimates, T&D losses in the power sector amounted to `45,000 crore for the fiscal year ended March 31,

2010. The government is leaving no stone unturned to reduce it to 15%.

O


INDUSTRY DYNAMICS

These losses can be reduced by using good quality wires and cables. Commenting on the significance of using good quality wires and cables, Goyal avers, “Good quality wires play a significant role in production. It saves electricity and improves efficiency.” Additionally, the government is also going for capacity addition of about 1 lakh MW in the 12th Five Year Plan, thereby creating a huge demand for wires and cables-based solutions. Telecom Several initiatives undertaken by the country’s telecom industry have fuelled the demand for wires and cables. One such initiative is making Internet access available in rural India as well as the introduction of new technologies like 3G and newer broadband services. Making these services available to the entire geographic region would require establishing a large number of transmission towers. This, in turn, would create tremendous potential for the growth of the wires and cables industry—a demand, which traditionally, was created by telephones and mobile phones. Railways Over the last few years, rail freight traffic has witnessed an annual growth rate of 7–11%. The freight volume carried by Indian Railways has increased from 670 million tonne in 2005–06 to 890 million tonne in 2009–10. By the end of the 12th Plan period, Indian Railways is expected to carry about 1.5 billion tonne of freight traffic. Railways aims to increase its market share of freight movement in the country from the current 35% to at least 50% by the end of this decade.

In order to serve such high levels of anticipated growth, Railways will need to expand its network across the country. Initiatives by Railways in this regard will create huge opportunities for the implementation of wires and cables.

STRICT GUIDELINES IN MANUFACTURING Due to the global meltdown in 2008 and the consequent liquidity crunch among companies, the industry experienced a severe drop from the peak demand witnessed in 2007. It was only during 2008–09 and 2009–10 that the industry saw a marginal growth. Manufacturers of wires and cables-based solutions have constantly implemented new technologies in the manufacturing processes so that they continue to remain competitive in the market. With an aim to reduce electrical losses, wires and cables manufacturing companies are trying to implement newer technologies in manufacturing.

Averring that companies today are adapting new and improved technologies to reduce electrical losses, Naveen Gupta, Director, Chetan Cabletronics,

says, “We use only the best of materials and equipment complemented by unique & stringent quality checks at every stage of the manufacturing process.” He adds, “The implementation of modern technologies has taken a giant leap, especially in the last 7–10 years, towards the manufacturing of wires and cables. We will see more technological innovations over a period of time.”

About a decade ago, many power companies were using 1.1 KV PVC-insulated cables for distributing power. But now, most of them are also using XLPE cables, with increased voltages, in order to reduce losses. The State Electricity Boards remain the major buyers for power cables. Small buyers of power cables also include companies having their own power distribution within plant limits based on their own need-patterns.

ENVIRONMENTAL IMPERATIVES Many quality-conscious companies are looking to develop wires and cables keeping in mind environmental norms. Gupta proudly says that his company’s products are backed by ISO 9001:2000 certification for quality management; ISO 14001:2004 certification for best environmental practices and IS 694:1990 for complying with state-of-the-art testing benchmarks.

To this, Goyal adds, “Our testing lab is ISO:694:1990 certified and the entire testing process complies with international standards.” The company also manufactures cables as per Restriction of Certain Hazardous Substances (RoHS) standards to cater to their global clients, especially from Europe and the US.

Talking about the benefits of using environment-friendly state-of-the-

art technologies, Gupta states, “Earlier, controlling scrap was a major issue during cable production. But now, with X-ray scanners and controllers, the generation of scrap has dramatically reduced. Further, PLC-driven machines have facilitated machine controlling.”

OPPORTUNITIES GALORE India is planning to invest US$1 trillion in infrastructure. As per the Automotive Mission Plan 2006-16, the Indian Government is geared to double the automobile industry’s contribution to the country’s GDP by 2016. The 12th Plan targets to generate 1,00,000 MW of power, which will certainly ensure steady growth of the wires and cables industry. Furthermore, the government is making endeavours to provide the rural regions of India with broadband connections. Such a scenario will create huge demand for wires and cables-based solutions. This, in turn, will create a bright future for the wires and cables industry.

[email protected]

The implementation of modern technologies has taken a giant leap, especially in the last 7–10 years, towards the manufacturing of wires and cables. We will see more

technological innovations over a period of time.Naveen Gupta, Director, Chetan Cabletronics

WIRES & CABLES OPPORTUNITIES


T SUPRITA ANUPAM

Transmitting waves of GROWTH

Wires and cables are essential parts of transmission & distribution of not only electricity, but also of

telecommunication and infrastructure. These help connect the dots… the dots of space as well as time. And in due

course of time, they have become key carriers of the growth of industries.

he wires & cables industry had been growing at around 15% annually during 2003–08 owing to factors such as

liberalisation and the government’s focus on infrastructure and power sectors. In 2008, globally, the wires and cables industry witnessed a mere 4% growth, while the optical fibre segment experienced a growth rate of 9.3%. A look at some of the other factors which in future might obstruct its further growth…Erosion in margins/copper price hikeCopper and aluminium are mostly used for manufacturing wires and cables. India and China are big consumers of copper in the world. While China alone consumes 26% of the total consumption, the Indian demand for copper varies from 9% to 15% against the global demand of 4–5%.

For the past few years, the price of copper has been continuously going up in compliance with the Marshallian

l aw of economics. This

has led to an erosion in the margins of the wires

and cables industry. “Recently, the price of copper was $8,434 per tonne, while, now, it has reached $8,720 per tonne. Within a few days, it witnessed a hike of $300. This fluctuation sometimes becomes very difficult to manage,” informs Vimal Chand, Managing Partner, Flat Cables and Allied Products. “In 2008–09, many companies had to shut down their factories because of this price fluctuation, i.e., when the price of copper fell from $8,000 to $2,900,” he adds. Deficit in power generation targetThe Indian wires and cables industry primarily depends on electricity generation. More the power generation, more will be the transmission & distribution (T&D). India’s power target for the 11th Five Year Plan

(2007–11) was to generate 78,700 MW of electricity. But by the end of 2011, only 60% of the target could be achieved. Hence, the deficit in the expected power generation target

slowed the wires and cables industry’s growth.Dependency on other sectorsThe wires and cables industry’s growth is highly dependent on other sectors. Slowdown in real estate, and delay in coal supply to power plants are some of the factors that decide the future of the wires and cables industry. Commenting on the same, Divyesh Chapadia, CEO, Gujarat Wire & Metal Industries, explains, “Our market is dependent on IT, real estate and telecommunication. During recession, except telecom, all the industries were on the downfall. Subsequently, we too felt the heat.”Lack of skilled manpowerIndia is facing a dearth of skilled manpower in all the industries. Undoubtedly, the country has been producing educated manpower and churns out millions of degree holders every year. However, they are not skilled enough to fulfill the job requirements. Adding further, Chand

elaborates, “There is a huge deficit of technical talent and retaining technical talent is a big challenge.”Flooding of Chinese importsChina’s growing market share is posing a threat to the Indian wires and cables industry. By supplying wires and cables at comparatively lower prices,

China is gradually capturing lower market segments, such as low tension (LT) cables. According to Chapadia, “They are supplying cheap quality cables at comparatively lower prices.

The government must ensure quality standards of cables, which should be in compliance with RoHS and REACH. In this way, we can set a proper direction to ensure the growth of the

wires and cables industry as well as create a better future for our next generation.Vimal Chand, Managing Partner, Flat Cables and Allied Products

WIRES & CABLES OPPORTUNITIES


They do not follow the Restriction of Hazardous Substances (RoHS) norms, which is not good for India.”Wireless communicationWith wireless communication getting popular these days and more and more people adopting Wi-Fi, the dependency on wires & cables has dramatically reduced. In fact, many industries have almost discontinued the installation of LAN in their campuses.Green challengeEarlier, the wires and cables manufactured contained lead, cadmium, polybrominated diphenyl ethers, biphenyls and their compounds, which were hazardous and posed threats to the environment. Further, the plasticiser used in PVC to bring flexibility caused cancer. The EU has strictly banned the use of these materials under the RoHS EU Directive 2002/95/EC & Registration & Authorisation and Restriction of Chemicals (REACH) European Union Regulation (EC) 1907/2006. “In India, it is voluntary to be RoHS and REACH compliant. Customers like BOSCH, LG Electronics and Wipro ask for these compliances. We are already RoHS compliant and are heading towards REACH,” says Chand, adding, “But there are not many alternatives of phthalate, as more than 90% of plasticisers used today are phthalate material, which is a very dangerous compound. The other alternatives are costly.” Growth opportunitiesIn due course of time, the wires and cables industry has grown to become more sophisticated and specific. It has created new markets like extension wires and fibre-to-the-home (FTTH). The wires and cables industry prominently deals with four sectors, viz., consumer electronics, telecommunication, real estate & infrastructure and power. All these sectors are independent of each other. “As far as India is concerned, all are booming. Hence, we are expecting a growth rate of 10–15% in future,” Chand adds.

Also, security systems are the new gateways for wires and cables. According to Chand, “Safety and security has opened a new window.”Consumer electronicsConsumer electronics has witnessed enormous growth over the past few years and this trend is likely to continue. The consumers’ need has been growing and changing with technological development. This has created ample scope for the cables industry. Vimal recalls, “In 1995–96, when we had just

started our business, the demand for TV cables stood at thousands per year, but now, it is 22–24 lakh per year.”Growing demand for faster data servicesData revolution after 3G implementation has fuelled the growth of the wires and cables industry. 3G & FTTH services to cover all of India need a lot of optical fibres. Presently, India’s fibre consumption is approximately 13–14 million fibre km as compared to China’s consumption of 80 million fibre km. This clearly indicates that even though India has certainly come a long way, it still requires a lot of optical fibre cables to achieve rural access and good data delivery. Chapadia asserts, “There is a huge demand for optical fibre cables in India. Overall, for us, telecommunication is one of the sector’s having the highest demand.”InfrastructureIndian infrastructure has been on the development track. Thousands of kilometres of National Highways (NHs) are under construction. These need proper lighting; thereby creating huge demand for wires and cables. The demand for wires and cables is also high in Railways, owing to the metro and mono rail projects in various metro cities, including Mumbai.

STEPPING AHEADIndia has the fourth-largest optical fibre network in the world with a per capita length of 40 metre in contrast to China, where it is 197 metres and the US, where it is over 907 metres. Hence, there is a huge requirement for optical fibre cables in the near future. The 12th Plan (2012–17) targets to generate 1,00,000 MW of power, which will ensure steady growth of the wires and cables industry. However, for this to materialise, the government has to take some positive initiatives to bridge the gap between the targets and the actual performance.

[email protected]

Growing scope for cables

The Goverment of India has set the target of ‘Power For All By 2012’ to meet the energy requirements of the entire country by adding 78,000 MW of installed generation capacity by 2012. According to experts, the total demand for electricity will be above 950,000 MW by 2030. India has taken all the necessary steps to provide energy from renewable sources such as wind and solar power. In March 2011, the capacity of wind power in India stood at around 12,000 MW.

Estimated Capex (` in billion)

FY10–17

Generation 8,533

T&D 5,006

Transmission 2,821.40

Distribution 2,184.70

Total 13,539

Consequently, expenditure on cables will be:

Estimated Capex (` in billion)

FY10–17

Generation 256

T&D 1,251

Transmission 705

Distribution 546

Total 1,507

The positive trend in the power sector is the most important catalyst for the wires & cables industry. Cables play a crucial role in all the three aspects of the power sector, viz., generation, transmission and distribution. So, the trend of wires and cables industry is, to a great extent, dependent on the power sector.

WIRES AND CABLES OUTLOOK


or decades, scientists have been fascinated with the idea of telepathy. This fascination has brought about a revolution in the

field of communication, healthcare, entertainment and energy in the form of wireless technology. According to Dr Ranjan Bose, Professor – Electrical Department, IITD, “Healthcare, entertainment, mobile communication and energy are the four pillars of wireless communication, wherein wireless technology has been successfully implemented.”

But, is the wireless revolution actually posing a threat to the growth of the wires and cables industry? Will it

really limit its future growth prospects? Let’s attempt to find answers to these queries by tracking the ‘wireless evolution’ till date…

COMMUNICATIONCommunication has grown to become one of the biggest markets in the world with companies such as Apple, AT&T and Verizon, among others, cashing in on it. With WLAN, Wi-Fi, GSM, CDMA and now W-CDMA (UMTS) entering the world of communication, wireless has captured almost all forms of data and voice communication. Commenting on the same, Vimal Chand, Managing Partner, Flat Cables and Allied Products, says, “Yes, wireless

communication has affected the wires and cables industry to some extent. But then, within the wires & cables industry itself, there have been so many innovations. In due course of time, the industry has found applicability in various other markets—such as security & systems—which offer the industry scope to maintain and enhance its growth rate.”

Adding further, Bose explains, “When it comes to long distance communication, using optical fibre is preferred, considering its better lifespan and superior signal strength with respect to satellite communication. This option, however, is costlier. But in case of short distances, like within a zone,

Ideas do not need any support to evolve, but technology does. Did you ever imagine a world free of wires and cables in the future? With WLAN, Wi-Fi, GSM, CDMA and now W-CDMA (UMTS) being a reality, you do not have to imagine it. Wireless technology has captured almost all forms of data and voice communication. With this reality intact, the debate on whether wireless technology will pose a threat to the future of the wires & cables industry continues. While there is no clear answer, here’s an attempt to gauge the future…

F SUPRITA ANUPAM

Are we heading towards a W

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WIRES AND CABLES OUTLOOK


city or house, going wireless might seem more viable.”

HEALTHCAREHealthcare is a field, where wireless usage is becoming essential with further tech upgradation. However, there is still more room to improve healthcare services by enhancing connectivity and communication between patients & their caretakers. Through wireless, one can explore the opportunities to promote the extension of healthcare beyond hospitals, clinics and doctors’ offices to patients’ homes and other locations.

The shape of future healthcare will thus be based on the optimum utilisation of wireless apps, wherein you need not go to hospitals for any kind of consultation or checkup (such as X-rays, ultrasound etc.). While being at home, all the required procedures will be performed wirelessly (even the medical report will reach your home). Kush Tripathi, Research Fellow – Biomedical, IISc, Bengaluru, avers, “Advancements have already taken place at separate levels. These need to be combined to revolutionise the whole sector.”

ENTERTAINMENTEntertainment is getting wireless not due to need, but due to fascination. The latest case in point is mobile phones wherein the development of multi antennas and software has enabled mobile multimedia services. Thanks to Wireless Gigabit Alliance, the 60Ghz frequency can now be used for home appliances as well as personal appliances like notebooks, etc.

According to Tal Tamir, CEO, Wilocity, “The 60 GHz Wireless Gigabit Alliance specification marks a fundamental breakthrough for home and business customers. WiGig-enabled notebooks and CE devices will now have wireless access to any interface, protocol and connection at unprecedented speeds. As a result,

Wilocity’s 60 GHz solution will enable people to determine their computing experience by giving them exactly what they want, instead of what they can carry.”

ENERGYWireless is very helpful in promoting the green energy concept. “It is also trying to minimise energy waste in many senses,” Bose states. But how can energy be transferred wirelessly? Well, there are many ways of doing it. Energy can be transferred wirelessly via radio waves and lasers by which low levels of energy or even the concentrated levels can be transferred. Wireless transmission depends on the resonance and circuits enabling resonant frequency. Marlin Soljacic, Assistant Professor – Department of Physics, MIT, and his team figured that magnetic resonance could be the answer to transfer electrical energy wirelessly. They succeeded in doing so while transferring it with 40% efficiency.

THE COGNITIVE DISSONANCEThe wireless industry is witnessing a boom. Wireless technologies are creating enough cognitive dissonance for the wires & cables industry and, like the audio & video cassettes industries, somewhere it could outcaste the wires and cables industry.

In order to retain its presence, the wires and cables industry needs to keep certain factors in mind. These include: Innovations in telephone cables: Around 15 years ago, telephone wires were essential means of communication. But now, it has become optional. Therefore, there is a need for innovations—such as fibre-to-the-home (FTTH) or fibre-

to-the-premises (FTTP) cable concepts—in this regard to keep the grand old aura of telephone cables alive.Flexibility: The biggest reason behind the success of wireless is its flexibility. It is

not that wires and cables cannot be flexible. With innovations like the nano-tube cable tethers, it can be made much more flexible. This, in turn, will help it maintain its market leadership position.Ad hoc communication: Disaster management teams prefer wireless communication because it is easy to install and establish. And with calamities like earthquakes, floods and wars, more and more countries, including Japan & Mexico have begun to opt for wireless communication forms. In such a scenario, the wires and cables industry needs to come up with an alternate ad hoc communication solution, which is easier to install. Eco-friendly and efficient wires: Copper is considered the best possible means of transmission. So far, there is no alternative (aluminium is way behind). Copper is certainly good for power transfer, but not the best. Once the superconductivity at room temperature becomes feasible, wires and cables will become much more efficient. Further, there is a need to develop more and more eco-friendly alternatives of plastic coatings.

WIRES AND CABLES HAVE A CHANCE Wires and cables have their strengths over wireless technology, which will keep them relevant to the industry. According to Bose, “Using too much wireless technology is more hazardous than using cables.” The other prolem with going wireless is the threat to security because wireless technologies are still not as robust as wires & cables are, in terms of safety and security. This provides plenty of room for the growth of the wires and cables industry.

[email protected]

The wireless industry is witnessing a boom. Wireless technologies are creating enough cognitive dissonance for the wires & cables industry and, like the audio & video cassettes industries, somewhere it might outcaste the wires and cables industry.

FACT

FACT

FACT

POWER CABLES


n the present technologically advanced cable industry, power cables are designed so as to withstand temperature

fluctuations, pressures, high voltage load and extreme weather situations as well. Still, there is every possibility of these cables getting damaged due to adverse installation conditions & unintentional damage during the laying of a cable. Also, severe mechanical or lightning damage cannot be ruled out.

Some of the other reasons for cable damage include deterioration due to age; gradual damage due to termite activity, rodents, microorganisms, soil chemicals, and temperature effects (contraction and expansion).

It has been observed that migration of moisture into cable insulation accounts for the maximum numbers of cable failures. When the insulation is punctured in power cables, moisture enters the damaged region and creates current leakage paths. Initially, a small

leakage current flows but this current creates heat, and heat tends to char the insulation. This process may continue for weeks or even months, before the leakage becomes big enough to make the cable unserviceable. Under these situations, taking up maintenance activity will not only ensure complete visibility into the condition of the power cable but also curb power failures.

USING TIME-TESTED METHODS Effective protection and maintenance methods are the most feasible, economical, and easiest ways to avoid damage to the cable. This requires periodic testing, inspection and maintenance of records. Cable record findings: As per a research paper, by keeping a record and comparing the readings each time a cable is tested, indications become clear about when a cable starts deteriorating rapidly or when the cable

failure is imminent. If the insulation resistance between conductors or between conductors and ground remains constant, the cable condition

remains unchanged. However, any appreciable drop in insulation

resistance indicates that the insulation or dielectric is deteriorating rapidly, and it may be necessary to repair or replace the cable. Visual inspection: While underground cable cannot be completely inspected, one should walk the route of the cable. Look for excavations, washouts, rodent activity, ploughing or planting, recently installed stakes or posts, or any other evidence of possible cable damage. Examine all cable ends and potheads for faulty sealing, discoloration, or

I

For any power utility company, complete visibility into the condition of its power cable networks has become critical to guarantee reliable, secure & uninterrupted power supply. Thus, maintenance of power cables has turned out to be a critical aspect in order to save on costs as well as ensure human safety.

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POWER CABLES

other evidence of heating or arcing. In the case of an overhead cable, the entire cable route should be walked and closely inspected. Any defects found should be repaired promptly.Cable load and voltage loss: The size of the cable, which is installed, is determined when the system is designed. However, changes in equipment or the addition of new equipment may increase the load. Therefore, the load current must be measured periodically. If the ampacity of a cable is exceeded, excessive power is expended in the cable in the form of heat. The heating effects in turn can damage or wholly break down the insulation. A cable may also be checked for overload by measuring the current in its conductors with a clamp-on ammeter. The measured current of any conductor should never exceed the maximum allowable ampacity for the wire size at the ambient temperature. Voltage drop: Checking the voltage drop of a cable is a matter of measuring the voltage applied to the cable, and measuring the output voltage at the load end of the cable. For low-voltage circuits, the voltage drop should not exceed l% of the applied voltage. Voltage drop is not usually found in EHV or HV cables, but it is observed in LT cables. Detection of PD: For several years, detection and localisation of partial discharges (PD) using AC voltages has been internationally accepted as a symptomatic, reliable diagnostic method for determination of the quality of insulation systems. Testing the quality of cable insulation may disclose an impending fault before complete failure occurs. Partial discharges, hot spots, mechanical cracks and changes of insulation dielectric properties, all indicate ageing trends. The best way to evaluate the quality of these medium voltage cable (MVC) are partial discharge measurement and Tan delta measurement.Restoration: Maintenance also involves technical measures including supervision

of the cable circuit and restoration of the cable network in order to ensure that the cable circuit performance is optimum under the existing condition. The maintenance can be grouped under preventive maintenance, predictive maintenance and time-based maintenance. In preventive maintenance, techniques like routine inspection of the cable routes and preventing the damage of the cable by the third party are adopted. Inspection

of the cable terminations and cleaning the external surface at regular intervals will enhance the system reliability of the cable network.

In time-based maintenance, once the electrical parameters of the cable network have been measured e.g. Tan delta, capacitance, insulation resistance, it is possible to infer the health of the cable from that point of time. In case Tan delta is higher than normal expected value, then

Having gained a handful of information on the best in class maintenance practices, let’s take a look at the methods adopted by major power companies… Alstom T&D IndiaInforming about the innovative measures, Rupanjan Bhattacharjee, Commercial Head, ISN, Alstom T&D India, elaborates, “During maintenance, underground cables are checked at both the ends. We conduct periodic testing, as well as visual inspection. Mobile monitoring is also carried out with the help of fault locating devices, which is mounted on a vehicle. However, mobile monitoring is carried out only if a fault has already been identifi ed in the cable through periodic testing.Explaining the applicability of other maintenance techniques, he says, “Time-based maintenance is mostly done for underground cables. While in predictive maintenance, we check the temperature of the cable. Normally, we have a schedule in which we carry out predictive maintenance so that we do not get into a situation where we have to force maintain the cables. Informing about the innovative techniques used at Alstom Grid, Bhattacharjee, explains, “We, sometimes, carry out thermal imaging of the cable terminations to see if there are any hot spots. This technique is used when the cable is already running. It helps us to identify whether the connection in the terminal has loosened or not. Most frequently, we carry out periodic testing, visual inspection and maintain the records. These are the three main techniques. If there is an abnormal situation that has been found after these initial tests, then we get into the diagnosis of the problem with the help of other techniques.”Tata PowerTata Power also follows certain procedures in ensuring apt maintenance of power cables. Throwing light on the mechanisms adopted, maintenance expert from Tata Power informs, “When the initial laying is done, there are chances that the cable may get damaged due to several factors. So, a sheath test is carried out in which, 10 kV of voltage is passed through an EHV cable and the test is carried out for that particular voltage. Also, we do predictive maintenance for gas, oil fi eld cables and paper cables. Under this method, we inspect the oil levels at all places where gauges are placed. We have pressure tanks fi tted as per the load cycle in the cable. If there is a leak, we pump in the oil and then try to fi nd out where the oil leak is. This is called oil testing.”Elaborating the unique methods used at Tata Power, he says, “Time domain refl ection is used to detect faults in the cable. To test an underground cable, visible testing is not applicable. In this case, we dissipate energy into the cable so that weak points are developed at different locations. For this, we test the cable at normal voltage and keep the EHV cable charged for one day.”Inputs taken by Sumedha Mahorey

FROM THEORY TO PRACTICE

POWER CABLES


it is advisable to carry out such measurements periodically to check the deterioration of the cable insulation. If the capacitance value is higher than that of the GTP value, there is every possibility that the water ingress into the insulation is causing the effect. Polarisation Index (PI): This is the simplest technique by which the quality of the bulk of the insulation can be checked. The ratio of insulation resistance of 10 minutes to that of one minute will give the PI value. Irrespective of the type of cable insulation, this is a very effective tool. Some experts are of the opinion that this value is more that 1.0 then the cable insulation is good. The test voltage can be either 1kVDC or 2.5 kVDC depending on the voltage rating of the cable being tested. Sheath Damage Test: The sheath integrity is a very vital test for all cables, as this will give a feedback of damage

of the outer sheath during the laying of the cable. In case of damage of the outer sheath, the defective location needs to be repaired before filling the earth. This will help in long term life of the metallic sheath, as water when comes in contact with the metallic sheath will initiate chemical reaction. Mobile monitoring: This can greatly

reduce the maintenance cost and supply more accurate status of the local cables over traditional monitoring techniques. The application range of condition-based maintenance can be expanded greatly with the aid of mobile monitoring.

DEVELOPING A MAINTENANCE POLICYAlthough a company implements proper maintenance practices,

development of a maintenance policy to prevent future problems with the cable system and ensuring safe operation is a must. Some of the pointers that can guarantee effective maintenance thus include having a clear maintenance strategy that is reviewed periodically; maintaining & evaluation of database of cable system failures, and investigation

of these failures. At present, utilisation of GPS in mapping cable routes and fault recognition are also coming up as

part of the maintenance strategy. With a clearly defined maintenance strategy in place and technology enabling this maintenance activity, cost benefits are sure to be derived while ensuring human safety and quality output.

Courtesy: S Ramaprasath, KP Meena,

Thirumurthy, GK Raja and A Sudhindra,

Central Power Research Institute, Bangalore

Effective protection and maintenance methods are the most feasible, economical, and easiest ways to avoid damage

to the cable. This requires periodic testing, inspection and maintenance of records.

TATA POWER


nspired by a powerful vision, the founders of Tata Power—India’s largest integrated private power company—

pioneered the generation of electricity in India with the commissioning of India’s first large hydro-electric project in 1915. Today, Tata Power has an installed generating capacity of 5,297 MW and a presence across the entire value chain in generation (thermal, hydro, solar and wind) transmission, distribution and trading.

Tata Power has been associated with the growing legacy of Mumbai as a business city for almost a century now.

The thermal power stations of the company are located at Trombay in Mumbai, Jojobera in Jharkhand, Haldia in West Bengal and Belgaum in Karnataka. As one travels the road to Tata Power’s thermal power generation facility at Trombay, one realises the effect of the presence of vital

organisations like Hindustan Petroleum Corporation Ltd (HPCL), Bharat Petroleum Corporation Ltd (BPCL) and the famous, Bhabha Atomic Research Centre (BARC) in the vicinity.

WINNING TECHNIQUE Established in 1956, Tata Power’s 1,580 MW capacity power plant at Trombay, today roughly meets around 70% of Mumbai’s power demands. Even during catastrophes like the July 2005 deluge, Tata Power supplied

Mumbaikars with uninterrupted

power. So, what is the reason behind Tata Power’s impeccable performance? The answer lies in the safety measures that have been implemented at the Trombay facility for which the company has been awarded the top honour for stable and outstanding safety performance, at the 10th Annual Greentech Safety Award 2011 by

the Greentech Foundation.

Tata Power has managed to achieve this feat by adopting some strategic measures at its facility, which

In the industry, some lead by example and the rest merely follow. Not wanting to follow someone else’s footsteps, Tata Power’s thermal power generation facility at Trombay has implemented many innovative initiatives in enhancing operational safety and security. It would be correct to assert that they are demonstrating to the world how to build an integrated safety approach in an organisation. Our recent visit to this iconic facility brought to the fore the world-class safety practices imbibed & practiced at this plant.

I SUMEDHA MAHOREY & VISHESH SHARMA

Best in class safety practices implemented at Tata Power All the meetings start with ‘safety contact’. Here, one of the employees would

delve upon handy safety & security tips All the incidents are investigated, i.e., there is 100% incident investigation &

CAPA implementation. The investigations are led by the line management STOP Observation’s proactive intervention is a behavioural-based safety

observation, which helps avert many potential injuries Raising & monitoring unsafe conditions/safety issues defects through SAP High-risk jobs are identifi ed and monitored by the Division Head. The concerned

department prepares a ‘Job Safety Analysis’ (JSA) approved by Section Head for this critical job. This plan is discussed with the Division Head while conducting a site visit to ensure that all the safety precautions are complied with

Personal Safety Action Plans (PSAP) are initiated with leaders from HOD & above and are extended to all the employees in management grade.

Taking an integrated approachTowards Safety

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is divided into several units—presently units 5, 6, 7 and 8 are being operated at the plant.

KEEPING THREATS AT BAYThe Tata Power management, at its Trombay facility, has attached significant importance to human as well as process safety. The safety rules are religiously followed by one and all. No wonder, they insist on wearing all safety gears including helmet, protective mask, earplugs and boots, before taking you on a tour of the facility. The facility made up of several units is huge and preventing it from incidents such as fires and accidents, among others is no mean feat.

According to PC Sridher, Head – OH&S, Tata Power, the following measures have helped us achieve its safety & security goal: Being an electricity

generation facility, there are various risks involved. However, Tata Power has worked towards minimising them. The whole process has been directed towards implementing benchmark practices. This is why the company has received an ISO 9001:2000 Certification: upgrading to ISO 9001:2008; ISO 14001 Certification; OHSAS 18001 Certification and an NABL-accredited chemical lab.

The company has set up a four-tier safety committee that involve

employees of various levels and disciplines to look into every aspect of safety. The Safety Steering Committee (SSC) sets safety policies and targets. The Regional Apex Committee facilitates and oversees the implementation of safety requirement in their respective regions. There is also a STOP Observations (SO) sub-committee, which focusses on addressing unsafe acts that constitute around 80% of incidents. Apart from that, there is a Rules & Procedure (R&P) sub-committee to develop/update critical safety procedures. Its purview is extended to reviewing and updating standard operating procedures (SOPs) and maintenance procedures. The Incident Investigation Committee ensures all the incidents, however minor, are systematically investigated and all the necessary corrective and preventive actions (CAPA) are implemented. Besides this, there is also a capability building sub-committee that focusses on safety competency development at all levels of the organisation and the contractor community. Last, but not the least, there is the activity

and involvement sub-committee, which focusses on off-the-job safety. This sub-committee spreads safety awareness in residential colonies and visual management at sites and colonies. Thus, the company is not only concerned about the plant, but also about the nearby areas.The company has made significant

investments to reduce workplace accidents and ensure a safe working environment.

Even small aspects have been given due importance. One look at the interiors gives you the feel that the company is serious about setting standards. The facility has clearly demarcated walkways for pedestrians and vehicle tracks for safe vehicle movements. There are also huge signboards cautioning people not to trespass into specific areas. While these may seem insignificant, they go a long way in ensuring the safety of employees.

MITIGATING EXTERNAL THREATSUndoubtedly, the company has implemented critical measures to take care of internal security. But the company also takes care of external security. When you see a coal-bed jetty at the backyard, conveyor belts directly transporting coal from the sea side, oil pipe lines via sea route, you are bound to wonder how this huge infrastructure is protected. In addition, there are giant oil storage tanks adjacent to the facility. Given this scenario, what are the emergency plans in place, in case of an accidental fire?Security team to the rescue On land

Managing these threats is the responsibility of the security team at

Tata Power, which is headed by Col Pradeep Dalvi, a proud ex-Army officer. Explaining how the security team manages to safeguard this huge infrastructure, Col Dalvi asserts, “We have done away with the concept of having more manpower for keeping the premises safe. We are

undergoing a transition to adopt the latest technologies that integrate with physical manpower. To begin with, the entire facility has been covered with electrical fencing and CCTV. So, whenever there is an intrusion, the security team would be warned of the same.”At sea

But what about the coastal side, where the coal-bed jetty for logistics is established?

Tata Power has taken concrete measures to ensure uninterrupted power supply through unique initiatives like sourcing of high-quality coal from Indonesia. This quality of coal also helps in curbing environmental pollution as it contains only 0.1% sulphur and 1–2% ash as compared to Indian coal, which produces almost 35% ash.

FACT

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Image Courtesy: Tata Power

TATA POWER


“The coastal side is very critical for us. Besides, we have to provide security to our mother ships that are anchored 10-12 miles away from the facility. For this, we have established a radar and automatic identification system. As a result, we are equipped to track any unidentified approach from the sea at the control room,” he explains. At the plant

Highlighting the security measures taken at the plant, Col Dalvi informs, “The Trombay facility is under electronic surveillance 24X7. We have built quick reaction teams and have also established immediate contact to the nearest police stations to tackle unwarranted activities. Besides this, mock drills in association with adjacent facilities are also conducted to check the preparedness in case of any emergency. Plus, sudden in-house drills are conducted to check employees’ preparedness in case of any incident.”

BENCHMARKS SET Tata Power has certainly set a benchmark in terms of safety and security systems for others to follow—a fact which is further reaffirmed after meeting various officials at the facility. While entering the control room, which produces 500 MW (peak load),

we asked the unit manager about the benchmark practices he follows. He informed: Since electricity theft is a major

issue facing the power transmission sector today, the company has adopted 220 kV transmission lines, from which stealing electricity is next to impossible.

While in the past, accidents occurred mainly due to the lack of communication between different departments. For example, if an operator unknowingly operates an equipment/appliance, which is under maintenance, an accident is bound to occur. However now, the company has introduced a lock out system. These are exclusive locks being used by the O&M personnel. The operating party and the maintenance party will put their own lock before the commencement of maintenance activity and remove the lock once the work is completed. This eliminates any inadvertent operation of an equipment which is

under maintenance. Also, in the 220 kV switchyard, the

normal porcelain insulators have been replaced with silicon coated insulators. Normal insulators develop sulphur films, which lead to cracks. These cracks could result in shrapnels, which would harm anyone working on the shop floor. However, the silicon coated insulators prevent the development of sulphur films.

BUILDING A FUTURE-READY FACTORYWith time, the security needs of the industry would also change. But with the arrival of so many technologies, what all improvements could be brought into the system? The security head replies that they are planning to upgrade to the IP-based cameras. The company has also acquired X-Ray scanning machines, like those placed at airports, to completely secure entry and exit points at the facility.

Sridher elaborates on the vision, “We are in the process of implementing the BSC 5-star Safety Management System (SMS). In this system, critical parameters like safety organisation; management control systems; fire control systems; measurement & control systems and safety implementation at workplace are closely embedded.”

With such exemplary measures already in place and many more to come up in the next couple of years, Tata Power will continue to set the benchmark in industrial safety and security practices. Concepts like SMS and use of hi-tech equipment and technology to enhance safety as well as security does not hamper the daily work culture. Instead, these concepts have been implemented and woven into the DNA of every person employed in the facility. Tata Power’s sheer dedication & imbibed discipline have ascertained that it ensures the integrated safety of employees, process and nature as well.

[email protected]

MAJOR ACHIEVEMENTS OF TATA POWER India’s fi rst 150 MW thermal unit First 500 MW thermal unit First gas-insulated switchgear Computerised grid control and energy

management system 220 kV transmission lines in four circuit towers 220 kV cable transmission network Flue gas

de-sulphurisation plant using sea water

SCADA and fi bre optics ground wire communication

Pump storage unit in the country of 150 MW capacity

POWER GENERATION AT TROMBAY

Unit 5 500 MW Oil, Coal & Gas

Unit 6 500 MW Oil & Gas

Unit 7 180 MW Gas

Unit 8 250 MW Coal

Total 1,430 MW

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DEVELOPMENT DYNAMICS


EThe increasing population, coupled with rising disposable income, has resulted in tremendous rise in domestic demand. The core sectors of power, oil & gas, cement, infrastructure and metals, among others, continue to scale up production to meet the burgeoning demand. While free trade agreements and economic partnerships will intensify competition, the overall manufacturing climate and relevant government/private initiatives are expected to augur well for the automation industry in the next few years.

conomic reforms and various policy initiatives have made India one of the fastest-growing economies in the world.

The manufacturing sector has played a significant role in the growth of the Indian economy, contributing nearly 15% to India’s GDP over the years.

The competitiveness of India’s manufacturing sector is critical for sustaining the growth of the Indian economy. Thus, to develop the manufacturing sector further, the government has announced the National Manufacturing Policy, which aims at increasing the share of manufacturing in GDP to 25% by 2022, from the current 15%. The heightened industrial investment has contributed to the growth of the automation market—this includes Programmable Logic Controllers-Human Machine Interface (PLC-HMI), Supervisory Control and Data Acquisition (SCADA), Distributed Control System (DCS) and Electrical Drives (AC, DC and Servo Drives), among

others. Contribution from major end user industries: PLC and related HMI: Auto, auto

ancillary and food & beverage constitute more than 30% of the PLC and related opportunity

Plant SCADA: Oil & gas and water & wastewater are the top two sectors for the plant SCADA market with a cumulative share of 20%

DCS: Power generation and oil & gas (upstream and downstream) are the top two sectors with a market share of more than 50%

Electrical Drives: Rotating equipment is the single largest end user sector for electrical drives with a market share in excess of 30%.

MAJOR DEVELOPMENTS IN 2011 Yaskawa started assembling AC

drives in its facility at Bengaluru Increased presence of Chinese and

Taiwanese players (especially HMI) Restructured Accelerated Power

Development and Reform Programme (R-APDRP) initiatives boosted the SCADA market

THE CEO’S PERSPECTIVE OF THE COMPLEX BUSINESS UNIVERSETechnology ImpactOpportunities

R-APDRP initiatives by the Government of India facilitate greater usage of automation and data acquisition systems, contributing to significant reduction in transmission & distribution losses

Ultra Mega Power Projects, involving supercritical generation technology, will increase the scale of automation

Preference for touchscreen—HMI over panel-based ones

Replacement of DC drives by AC drives

Expanding DCS functionalities resulting in reduced PLC usage

Challenges

Budget constraints, coupled with higher cost of automation products deters technology adoption

Global ScaleOpportunities

India is emerging as a preferred sourcing destination for automation

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products (such as electrical drives) Increased presence of IT and

software vendors in the global SCADA market

IT vendors as system integrators for software products

Rising exports to APAC and Middle Eastern countries

Challenges

Acceptance of domestic (assembled) automation products

Lack of relevant semiconductor/electronic infrastructure setup

Adherence to global regulations Uncertainty in global economy

End User PerspectiveOpportunities

A strict regulatory framework facilitates greater usage of automation systems

Ultra Mega Power Plants (UMPP) will increase the opportunities for automation systems

Challenges

Budgetary constraints Regulatory framework (US and

Europe FDA regulations; pharmaceutical sector)

Limited awareness, SMEs in particular, about the cost-benefit equation

Industry ConvergenceOpportunities

Various leading software companies in India are partnering with automation solution providers to implement/support level 2 & 3 automation products such as HMI, SCADA and Manufacturing Execution System (MES), etc.

Level 4 automation companies such as SAP and Oracle are moving to level 3 to provide automation products such as MES

Challenge

Domain expertise

STRATEGIC OUTLOOK FOR 2020Automation trends and opportunities have been mapped across five core sectors:Power Large-sized power projects coerce

greater opportunities Integrating process and business to

achieve higher process optimisation, monitoring real-time performance and improving profitability

Power trading and R-APDRP initiatives to facilitate greater adoption of data acquisition and monitoring solutions

Growing participation of Chinese and Korean contractors in India facilitate increased penetration of automation vendors

Oil & Gas Network safety in the face of

increasing concerns over the security of oil & gas infrastructure

New LNG terminals and expansion of existing terminals

City gas distribution projectsCement Integrating Laboratory Automation

and Quality Management System with the plant control

Increased usage of medium voltage electrical drives

Energy-intensive nature of the industry thereby leading to widespread adoption of energy management solutions such as energy dashboards and report generation

Consolidation in the Indian cement industry & increased globalisation

Infrastructure Greater emphasis on railway

scheduling and safety will drive the demand for railway management & monitoring system

Metro rail projects Construction of new ports/airports

& modernisation of existing onesMetals & Mining Perform Achieve Trade (PAT)

scheme will facilitate the adoption of energy management solutions

Widespread implementation of MES to manage production s c h e d u l i n g — m a n u f a c t u r i n g operations

Consolidation in the global mining industry necessitates the usage of asset management software, among others

Entry of global steel manufacturers (such as POSCO & Arcelor Mittal) and global acquisitions (such as Tata Steel’s acquisition of Corus & Hindalco’s acquisition of Novelis) will translate into the adoption of global best practices

GOVERNMENT ANNOUNCEMENTS 2011National Manufacturing Policy (NMP): The NMP got clearance from the Cabinet in October 2011. The policy aims to increase the share of manufacturing in GDP to 25% by 2022, from the current level of 15%. This policy will lead to the creation of National Investment and Manufacturing Zones (NIMZs) in the country.Impact of NMP on the automation sector: The planned increase in the manufacturing activity will boost the demand for automation products. Indo-Japan Comprehensive Economic Partnership Agreement (CEPA)India and Japan have entered into a CEPA, which will boost bilateral trade between the two countries to US$25 billion over 10 years from the current US$10.3 billion. Impact of CEPA on the automation sector: Under CEPA, the import duty on completely built drives originating from Japan will be 0%. Thus, the Indian market will witness the entry of many Japanese drive vendors and an intensified price war.

EXPECTED ANNOUNCEMENTSGoods and Services Tax (GST): GST will replace the indirect tax regime in India. The dual GST will have Central and State GST levied concurrently by the Centre and states. Impact of GST on the automation sector: GST will impact all aspects of businesses; pricing of products & services and supply chain optimisation.

Industrial Automation & Process Control

Practice, Frost & Sullivan, South Asia &

Middle East


hotovol ta ic (PV) technologies exploit the inexhaustible energy of the sun to meet the growing global demand

for electricity without the (indirect) environmental and socio-economic costs associated with fossil fuels. PV has seen unprecedented growth over the last several years, with more than 79,000 MWp now installed globally. Although PV does not generate emissions during normal operation,

there could be adverse impacts during raw material sourcing, production and end-of-life recovery stages. All these aspects should be considered when assessing the overall environmental impact of the technology.

By replacing fossil fuel combustion with PV to generate electricity, we can cut down the emission of greenhouse gases and of several other pollutants that threaten the environment and human health, such as nitrogen oxides (NOx), sulphur dioxide (SO

2), particulate and

heavy metals. Indeed, according to evaluations by independent scientific authorities, replacing European or US grid electricity with Cadmium telluride (CdTe PV) power plants amounts to 89–98% reduction of greenhouse gas emission, pollutants and heavy metals, including cadmium (Cd). For every GWh of electric energy produced, the lifecycle-Cd release of CdTe PV is over 100 times smaller than Cd air emissions from a fossil fuel power plant.

The Lifecycle Assessment (LCA)

PFuture energy generation technologies need to constructively address several key environmental and socio-economic issues without raising others. In line with this, Lifecycle Assessment (LCA) enables a fair comparison of different technology options and provides measures to minimise potentially negative impacts at all stages of the lifecycle of a technology. Taking First Solar as the case in point, and its implementation of LCA on photovoltaic modules, this feature analyses the LCA concept from ‘cradle to grave’...

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PHOTOVOLTAIC MODULES’ LIFECYCLE MANAGEMENT


approach provides insights into the different impacts and benefits from cradle to recycling of PV and provides a ‘level playing field’ basis of comparison with other energy producing technologies that should enlighten public debate on the ‘cost’ of solar electricity.

LIFECYCLE ASSESSMENTLCA addresses the environmental aspects and potential environmental impacts (e.g. use of resources and environmental consequences of releases) throughout a product’s lifecycle—from raw material acquisition through production, use, end-of-life treatment, recycling and final disposal (i.e. cradle-to-grave).LCA can assist in: Identifying opportunities to improve

the environmental performance of products at various points in their lifecycle

Informing decision-makers in the industry, government or NGOs (for the purpose of strategic planning, priority setting, product or process design or redesign)

Selecting relevant indicators of environmental performance, including measurement techniques

Marketing (implementing an eco-labelling scheme, making an environmental claim, or producing an environmental product declaration).As such, LCA provides a qualitative

and quantitative tool for policy makers and businesses to evaluate different technology options on a level playing field and taking into consideration the transfer of environmental impacts from one medium to another and from one lifecycle stage to another.

STARTING AT THE SOURCEFirst Solar has embraced the concept of Lifecycle Management based on LCA and looks at its product—which, in fact, is the provision of clean and affordable solar electricity—from the source to the recycling at end-of-life. Starting

at the source, First Solar’s innovative thin-film PV technology already utilises byproducts of base metal production to produce a stable and highly efficient semiconductor for use in its solar panels. CdTe—a stable metallic compound—is composed of byproducts from zinc and copper production.

FROM RAW MATERIALS TO PV MODULEThe next step in the lifecycle of the PV module actually has the biggest impact on the environmental profile over the whole lifecycle. Taking the raw materials and putting them together to create a CdTe PV module requires sophisticated manufacturing processes and obviously some input of energy and other resources. The production process, of course, also releases some effluents, which are not used further (and hence have to be counted into the overall balance).

The simple design of First Solar’s modules as frameless glass-glass laminate allows for very efficient

production, as well as for an effective recycling process at end-of-life. The innovative, fully integrated production process First Solar developed is beneficial to the overall footprint of the production process, which will be allocated to the electricity produced over the lifetime of the module to enable a fair comparison to other technologies. The energy consumed in this important stage of the lifecycle is sourced from the available grid mix at the production location. So, each kWh used for producing the modules carries a backpack of emissions and resource consumption, which now needs to be added to the environmental profile of the final module. Globalisation of the production of PV requires an analysis of the environmental impact, which takes country-specific production

processes into account. The country electricity mix influences the primary energy needed and carbon dioxide (CO

2)-equivalents emitted per kWh

produced. The electricity mix used for the production of polysilicon is often different from the country mix, but is also considered confidential in many cases. For the production of polysilicon, several manufacturers use hydropower or Combined Heat & Power (CHP)/Cogeneration, but exact data are missing. As a result, energy payback time and carbon footprint for equal factories differ based on the electricity mix used. In addition to this difference, due to the production location, the irradiation on the solar panel depends on the installation location.

TIME TO PAY BACKOnce the PV module is installed in a PV system and connected to convert sunlight into electricity, it is time to pay back the energy required to produce the module. The meter measures the environmental impact during raw material sourcing and production of the module, along with the Balance-of-System (BOS), which is necessary to complete the installation. In this stage, the meter will run backwards as it measures the immediate benefit of generating renewable energy.

The meter, which measures the payback time of First Solar’s PV technology, will reach zero faster than that measuring any other current PV technology when it comes to Energy Payback Time and CO

2 Payback.

These will be reached well before a year of operation of the system, depending on its location. This obviously gives tremendous benefits for the system’s lifetime, which could go well beyond 30 years. In addition to the environmental benefits, the economic benefits are similar.

The First Solar technology has the cheapest manufacturing costs and the levelised cost of electricity are the lowest as compared to all the other current PV technologies. The frameless design of

PV has seen unprecedented growth over the last several years, with more than 79,000 MWp now installed globally.FA

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PHOTOVOLTAIC MODULES’ LIFECYCLE MANAGEMENT

First Solar’s modules also minimises the need for cleaning, which helps in further improving the environmental performance of the modules during this phase of their lifecycle.

LAND USE AND BIODIVERSITYAn important issue related to the promotion of large-scale PV facilities is the compatibility of PV and agriculture. Several PV mounting solutions are under study to allow agricultural activity at the site of PV plants, and many solar power plant operators in Europe allow shepherds to graze sheep or goats on the same site. French law even requires the ‘dual use’ of ground-mounted solar systems on agricultural land with agricultural activities such as grazing sheep. PV power plants based on CdTe PV modules technology are safe and compatible with agriculture. Combining PV electricity production with agriculture can be very beneficial

for both activities.

CLOSING THE LOOP With more than 79,000 MW of PV installed worldwide at the end of 2011, and assuming approximately 100 tonne/MW, one day, there will be at least 7.8 million tonne of waste. Recycling not only benefits the environment by reducing the overall volume of waste, but also helps reduce the amount of energy required to gather raw materials, thereby reducing the costs and overall environmental impacts of producing PV modules. Furthermore, voluntary, producer-financed take-back and recycling enhances public support for the PV industry.

AVAILABLE PV RECYCLING TECHNOLOGIESIf one considers the composition of thin-film PV modules, the vast majority of the material used is glass. Taking other technologies into account, other valuable or rare materials include silicon

cells and semiconductor materials.

TAKING SUSTAINABILITY-MINDED DECISIONSA fair assessment of energy production technologies requires a common methodology to assess impacts and benefits of the kWh produced. Lifecycle assessment enables this comparison by basically adding the backpack of emissions, waste, etc. to each kWh produced over the complete lifecycle of the generation technology. Embracing this concept and integrating it into a lifecycle management approach enables First Solar to make conscious, sustainability-minded decisions on the development of the product, as well as voluntarily taking responsibility for the whole lifecycle of the product, and including its eventual collection and recycling.

Andreas Wade, Director, Sustainability, First

Solar, Inc.


UNION BUDGET 2012–13

As the Indian manufacturing sector moves towards attaining the ambitious target of 25% growth rate by 2022, high hopes were pinned on the Union Budget 2012–13. Yet again, this year’s Budget has not been able to strike a chord with one & all. Many term it as pragmatic as well as balanced and realistic, while others are still waiting for that magic wand to steer their growth. However, for the Finance Minister, this Budget was all about balancing growth and containing fi scal defi cit. Here’s presenting the opinions of who’s who of the manufacturing sector to gauge the future course of action…

TEAM SEARCH

BalancedAn attempt towards striking

G owth

Th e Finance Minister has presented a well thought out Budget. Th is will pep up the economy, which had slowed down due to some sectoral imbalances. He has paid special attention to the power sector, which needed expeditious expansion. Measures such as `10,000 crore tax-free bonds for the power sector, tax exemption for thermal power companies for two years, extension of the sunset clause, and the facilitates for coal mining with exemption from customs duty on machinery for mining & on imported coal, will speed up the development of new generating capacities ands improve the plant load factor.

Sanjiv Goenka, Chairman, RP-Sanjiv Goenka Group & Vice Chairman, CESC Ltd

We applaud the government for taking such positive steps. Th e Budget has rightfully laid emphasis on effi cient government spending in sectors, like infrastructure, that have a long-term impact on the economy, with a focus on improvements in areas like power. Progressive measures, such as increasing the tax-free bond limit for the power sector, reduction of withholding tax from 20% to 5% and exemption on customs duties for import of thermal fuels for power plants, will go a long way in reducing the fi nancial burden on the sector. Th is will ultimately benefi t both, the suppliers as well as the end consumers.

Banmali Agrawala, President & CEO, GE Energy India

Th e Budget consisted of many growth-oriented measures and also made eff orts towards fi scal consolidation. In particular, the timely focus on the infrastructure sector is welcome. An area of concern for the industry is the increase in excise duty and service tax from 10% to 12%. At a time when the industry is already facing huge increases in input cost, this will further add to the burden. It is possible that this may not yield the revenue that the Minister is looking for and instead, result in further slowdown in growth while adding to infl ationary pressure. CII welcomes the attempt at reversing the fi scal slippage of the current year by introducing amendments to the FRBM Act. Successful fi scal consolidation will be contingent upon widening of the tax base and better targeting of subsidies. Th e revenue and expenditure targets set for 2012–13 seem realistic and the fi scal defi cit of 5.1% of GDP is achievable. However, the borrowing level required to fi nance this defi cit is still high and will keep up the pressure on interest rates.

B Muthuraman, President, CII and Vice Chairman, Tata Steel

We welcome the Finance Minister’s recommendations for economic recovery, spurring growth, removing bottlenecks and promoting public private partnerships. Th e extended tax incentives, the decision to allow ECBs, and reinforcement of intention to introduce DTC and GST in the near future should create a positive investment climate. We also welcome the government’s continued interest in giving a boost to solar energy projects. Th e waiver for thermal power companies will benefi t upcoming projects. Th e removal of customs duty on imported coal, natural gas, LNG and the incentives for the mining sector will marginally improve coal supply. But it is still a far cry from achieving adequate fuel security. However, other measures including the Fuel Supply Agreements with Coal India Ltd should provide some relief. We expect stronger sustained steps to be taken beyond the Budget, to address the core issues faced by the power sector.

Anil Sardana, MD, Tata Power



Th e National Manufacturing Policy has been announced with the objective of raising (within a decade) the share of the manufacturing sector in GDP to 25% and creating 10 crore jobs. We see this as an advantage for the chemical sector, which has immense growth potential. Th e peak rate of basic customs duty remains unchanged, but the hike in excise duty and service tax from 10% to 12% would impact the manufacturing sector. Th e hike in excise duty for the automobile industry to an ad volerm rate of 27% could result in reduction in auto sales. So, it would be imperative for auto manufacturers to look at better technology, higher fuel effi ciency and various other measures to make it attractive for buyers. Th e proposal to extend weighted deduction of 200% for R&D expenditure in an in-house facility for a further period of fi ve years beyond March 31, 2012 is certainly a welcome step, which would encourage companies to focus more on research and development in the country.

Venkatesh Sankaran, Executive Director and CFO, LANXESS India

Th e power sector continues to sail on calm waters, as all major provisions for the sector remain unchanged. However, for the fi rst time, the Budget accorded importance to the principles imbibed under the National Action Plan on Climate Change (NAPCC), by allocating resources to the missions created under NAPCC and giving a strong mention to initiatives pertaining to renewable energy. Th e government’s unwavering support in building a low carbon economy is absolutely commendable. Th e allowance of ECB for the power sector is most welcome as it addresses the burgeoning energy needs of India. Along with signifi cant improvement in tax-free bonds for infrastructure funding, the reforms pave the way to lower the cost of fund, thereby making projects more viable for investors. Increased liquidity for putting up power projects is much needed and appreciated. Overall, it attempts to balance fi scal consolidation, and, at the same time, counteract the slowdown of our country’s GDP growth.

Tulsi Tanti, Chairman, Suzlon Energy Ltd

Th e government’s plan to introduce tax reforms for the enactment of the Direct Tax Code Bill is encouraging for us—a foreign corporation with an Indian subsidiary. Th e move to set up the GST network as a National Information Utility and operationalise it by August 2012 is also favourable for the industry. Th e Budget has also recognised the role of technology in creating a citizen- centric governance framework, refl ected in the subsidy provided for Aadhaar tablet-enabled payments for various government schemes in at least 50 districts within the next six months. Th e ambiguity on treating software as goods (subject to VAT) or as service (and subject to service tax) has not been cleared in the Budget. We were also hopeful of revisions around the Minimum Alternate Tax (MAT) on SEZ as last year it saw the investments in SEZs going down. Amendments towards this end would have helped the industry create a conducive environment to attract both local as well as foreign investments.

Sanjay Deshmukh, Area Vice President – India Subcontinent, Citrix Systems India Pvt Ltd

I think it is a fairly balanced Budget. For the manufacturing sector, there has been some tinkering, but nothing major as such. With the taxes going up on the service and excise fronts, it will leave a minor dampening eff ect in the short-term. But over a period of time, it will be addressed and absorbed. However, the industry was expecting some policy changes from this Budget; for example, FDI in insurance, retail, airline and so on. Th ese sectors need huge capital investments and today, India needs investments for growth. If India wants to attract foreign investments, the government will have to come up with policy initiatives in this direction.

Jagannadham Th unuguntla, Head – Research, SMC Global

I think given the fi scal constraints, the Finance Minister has done a good job. He tried his best to balance the Budget by increasing service tax and cutting down on subsidy. Overall, perhaps he could have cut more on the subsidy front, but having said that, he also had to balance high infl ation, which is denting the common man’s pocket. I think from an investor’s point of view, the government has done well for infrastructure. He has also announced certain measures in loans and debt funds for the power sector, cold storage, and food distribution segments. Investors, however, will be very cautious and would want to see the implementation of the proposed policies at the grassroot level. I think there is a framework, but execution is an issue in India, So, we have to wait and watch.

Gautam Bhandari, MD, Morgan Stanley India Services



Th e 2012 Union Budget is a mixed bag for the energy and resources sector. Th e government has attempted a balancing act while continuing with tax exemptions and benefi ts for power projects for another year till 31 March 2013 under section 80IA and providing additional depreciation of 20% in fi rst year, thereby enabling higher recovery of capital cost. Th e thermal power sector will also benefi t from the reduction in customs duty on coal as it will reduce their input cost. In the oil & gas space, direct subsidy in cash compared to bonds is expected to improve the cash and working capital position of oil & gas companies, particularly oil marketing companies, as they bear 24% of the subsidy burden. Besides, customs duty for some equipment used in exploration, production and mining has been brought down to nil, which can reduce the cost of operations.

Kalpana Jain, Senior Director, Deloitte Touche Tohmatsu India

Th e Union Budget has belied the expectations of the domestic electrical equipment industry, which was hoping for some corrective action from the government to rev up the downward slide of the industry. Th e slowdown in the power sector and escalating imports of electrical equipment, which led to sharp deceleration in the growth of the domestic electrical equipment industry this fi nancial year, have not been addressed. Th e power transmission and distribution sector has been largely ignored while the generation sector has received some attention. Th e hike in service tax and excise duty rates will further impact the top line and the bottom line of electrical equipment manufacturers, who are already facing a crunch and working at broadly 65% of their production capacities.

Ramesh Chandak, President, IEEMA and MD & CEO, KEC International Ltd

We can look at it as a status quo Budget. We were looking for more concrete initiatives that could quickly propel India’s growth and more specifi cally, increase the contribution of manufacturing from 16% to 25% of the country’s GDP. We hope that the government makes progress on the implementation of GST and early enactment of DTC to make this a truly favourable Budget. Also, the amendment to section 9 (transfer of shares) is a cause of concern for Eaton and other MNCs doing business in India.

Raja Kochar, MD – India, Eaton Corporation

Overall, its a tepid Budget with no big-bang measures that ensure the promised high growth trajectory, which India has been waiting for patiently for the past couple of years. Although it has been promised that the GST will be implemented from August 2012, it should not eventually turn out to be another failed promise as has happened in the past. One good development is the allowing of ECB in segments such as road construction and the target for highways development in FY13. Th is, coupled with the increase in the tax-free infrastructure bond allocation to `60,000 crore, will defi nitely help spur growth in the infrastructure sector.

Tushar Mehendale, MD, ElectroMech

Th is is a balanced Budget. Th e Finance Minister could not have come out with a better Budget given the challenges that the government is facing, especially in terms of fi scal defi cit. He has made a provision of `60,000 crore for infrastructure. Th is support will off er a boost to the development of all the sectors in the country. However, given the country’s high fi scal defi cit, he had to take the step of increasing the excise duty by 2%. A mere 2% hike will not have a major impact and therefore, should be accepted and absorbed by the industry.

Rajkumar Dhoot, President, ASSOCHAM and Member of Parliament

At the macro economic level, I think that the Budget is close to realism and still exudes cautious optimism. Th e Finance Minister has made a candid statement on the fi scal situation and clearly articulated directional intent on containing the subsidy. As far as infrastructure is concerned, the eligibility for viability gap funding is extended to a wider set of projects. Th is will boost infrastructure investment in several areas hitherto non-viable for private sector. Th e 100% increase for tax-free bonds from `30,000 crore to `60,000 crore is a huge positive, particularly with specifi c limit for ports and power sector at `5,000 crore and `10,000 crore respectively. Th e pioneering initiative of tax-free bonds for power up to `10,000 crore is a strong measure to boost investment- led growth in the power sector.

Gautam Adani, Chairman, Adani Group

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SAFETY LEADERSHIP

W PRERNA SHARMA

IMPLEMENTINGa top-down approach

elcome to the ‘Factory of the F u t u r e ’ , where the

underlying notion is not just about imbibing best in class technology & automation solutions, s t a t e - o f - t h e - a r t equipment and well laid out processes, it’s also about keeping up with the motto of ‘Zero Accidents & Injury’ and who better than a CEO can ‘walk the talk’. Today, working in an injury-free job shop is no longer a distant dream. It has become a reality, thanks to the growing involvement of the senior management in setting safety targets and imbibing the most stringent laws to percolate this very notion to employees working on the shop floor.

Going by the industry sentiments, it can be gauged that the preconceived notion of ‘safety must first be implemented at the bottom and work its way to the top’ has completely been transitioned into ‘safety starts from top’. Workplaces that achieved the highest levels of safety have done so by creating a culture that embraces safety and empowers employees to maintain a commitment to safety in everything they do. According to Tim Holman, Chief, German Township Fire & EMS, Clark County, Ohio, the leaders of the organisation must promote safety from top to down. The leaders set the example. The chief officers talk about safety and follow the rules that have been established. “I recently witnessed an assistant chief at the scene of a working house fire on the roof, operating a ventilation saw

wearing no turnout gear. In addition, he had not deployed a roof ladder. What message did he send to his firefighters? It should be no surprise that many of the firefighters at this scene were not wearing gloves, helmets and eye protection. This is a prime example of a ‘poor safety culture’ and it started with the leadership,” he says.

WORLD-CLASS SAFETY LEADERSHIPOne must remember that inculcating a safety culture in an organisation happens from top to down. If the top management is committed about inculcating safety habits in the people, only then will those habits get inculcated. Many a times, it happens that the top management gives only lip service to safety issues and conveniently bypass their own rules when there are, time or any other constraints. This sets a wrong precedence in the minds of the people within the organisation and hence, they come to look upon the safety rules as something, which are meant to be broken. Herein lies another hidden issue. People should feel within themselves, the need to

follow safety regulations rather than following them out of fear. Hence for inculcating

a safety culture within an organisat ion, focus should be more on training in safety measures and outlining the risks of not following those measures, rather than on imposing the rules by implementing a ‘fine’ culture. Paying a fine somehow ‘regularises’ non-compliance and thus, creates a wrong sentiment.

Giving an in depth perspective on the safety procedures followed in Indian facilities, Tushar Mehendale, MD, ElectroMech, informs, “In many companies in India, safety is sadly looked upon as a cost centre. There is no denying the fact that adopting safety measures does involve costs. However, many people tend to overlook the huge long-term benefits associated with a safe working environment and a ‘safety first’ culture. Hence, they fail to categorise safety costs as safety investments. A true leader will always attribute safety issues paramount importance, as ultimately, business nowadays is all about risk management. Effective risk management leads to elimination of a lot of variables that can affect the successful operations of any business. Hence, it is in the overall interest of the business to have a strong focus on safety related issues.”

SAFETY LEADERSHIP AT L&TWho can forget Larsen & Toubro, when it comes to displaying safety leadership? L&T is a classic example of practicing what they preach. The

Aptly described with the phrase ‘walk the talk’, today’s chief executive offi cers have a bigger responsibility in setting golden rules for safety & security and in ensuring that each & every employee of the organisation adheres to this discipline by will and not by force. In doing so, leaders have to keep in mind that they practice what they preach. Ultimately, the onus is on them to drive safety initiatives and become a responsible organisation while taking employees along their stride.

SAFETY LEADERSHIP


commitment of the senior management is testimony to the fact that the company takes the minutest of efforts to ensure safety at the workplace. The senior management makes sure that they are present during employee training sessions, so that they can percolate the notion of ‘safety starts at the top’ to its employees. This approach has been working wonders for the company. Since the last few years, the company has managed to ensure zero accidents at the workplace.

UNIQUE INITIATIVESBy now, it is clear that the leader plays a critical role in ensuring safety at the workplace. We bring to you some of the best in class practices followed by global majors to substantiate the same: ABBAt ABB, achieving a world-class health and safety performance is not only about having good systems, but also strong leadership and personal accountability at every level of the company. This means that safety starts with the leader. The frequency of incidents at ABB has decreased by 60% ever since ABB undertook the OHS initiatives in 2004, which ensured improvements in machinery & safety equipment as well as resulted in clear instructions and procedures being given.

But to reach the target of zero injuries at ABB, physical safety measures and processes are only one part of the challenge. ABB is therefore reinforcing its safety leadership concept under a new motto, ‘Safety starts with you’. According to ABB senior officials, personal commitment is crucial to building this kind of a culture: safety is our own responsibility and everybody at ABB—managers, employees and contractors—needs to take leadership. In addition to many business-specific OHS programmes, ABB also has a special safety leadership programme addressing the top management. It underlines the importance of personal engagement and setting a good

example. Managers have to visibly demonstrate safe behaviour, know and follow the rules, and ensure that their team members do the same. DowDow is known for programmes such as the ‘Drive to Zero’ safety initiative, representing an inclusive strategy with detailed execution in all phases of its operations. It also adheres to contractor safety training and commitment—believing everyone working at a Dow facility deserves to go home just as safe as when they arrived. According to Vipul Shah, President, CEO & Chairman, Dow Chemical International Pvt Ltd, Dow’s all Indian sites are Responsible Care Certified—a unique, global, chemical industry standard, which embraces

the development and application of sustainable chemistry. It has met the goal of zero process safety incident & motor vehicle accidents reduced by 45% as compared to the previous year. The company’s Chennai Coatings Plant has zero discharge and its PU Systems Plant at Kalwa has bagged the WRAP award in the Zero Effluent Discharge category. All of this was achieved as it was driven from the top and percolated till the last employee in the hierarchy. ElectroMech Employees of material handling

equipment major, ElectroMech, have to adhere to strict safety policies regarding working on the shop floor as well as at sites. Wearing basic personal protection equipment (PPEs) such as hard hats, safety shoes, safety goggles, etc., are mandatory for workers on the shop floor. To this, Mehendale informs, “We conduct regular training sessions for first aid, evacuation, etc. We have a designated safety officer working at our factory, who overlooks various aspects. We have standard safety practices in our offices. Apart from proper evacuation routes marked, we also have smoke detectors in place. A lot of our work gets done on sites and we have a stringent checklist for safety measures that are followed at site. We have daily tool box meetings. People working at heights have been trained in safe procedures to be adopted.”LanxessLANXESS, a global specialty chemicals company, has been taking various measures to enhance the awareness of safety protocols among employees and increase their alertness towards areas/situations that may lead to an incident in future. As part of the initiative, the company has been organising ‘Safety Week’ at each of its facility. Highlighting the importance of the same, Dr Joerg Strassburger, MD and Country Representative, LANXESS India, avows that recently, in Nagda, it started off with the distribution of safety badges to all employees, and an inauguration programme wherein they took an oath for being responsible for maintaining health & safety in the organisation. At their Jhagadia plant, several interactive programmes were conducted. This included a safety quiz for employees to gauge their levels of awareness, essay competition, the ‘Safety Man of the Year’ (selection based on an individual’s contribution towards safety), etc.

Here, two interesting concepts were introduced in this year’s celebration. One was identifying ‘What went wrong’ by picking up specific cases in point and

WAYS TO IMPROVE THE SAFETY CULTURE OF AN ORGANISATION The safety process must touch

every person in the organisation; Safety must be a permanent

agenda item, discussed at the start of every meeting;

Leaders must be held accountable for safety performance;

Safety must be the operational fabric of a facility, not a separate function; and

Safety must be integral to every business activity.


SAFETY LEADERSHIP

suggesting how such occurrences could be prevented in future. The other was asking employees to submit cases of ‘near miss accidents’ at the site that were observed throughout the year. These activities were aimed at employees’ own initiative of recognising potential causes of accidents and adopting measures for minimising them.

All of this has become possible with a strong commitment from the senior management. Strassburger informs, “All manufacturing sites of LANXESS in India have to mandatorily comply with the Health, Safety, Environment and Quality (HSEQ) policy, which mentions safety as one of the parameters that is accorded the same priority as commercial efficiency. Uniformly high standards for planning, constructing and operating facilities are applied to ensure the maximum possible process and plant safety. A comprehensive safety management system (SMS) sets out regulations, governing all safety-relevant processes

at production plants. Regular checks and intensive staff education and training programmes ensure that the SMS is implemented consistently and accidents are prevented.”

EMPLOYEE ENGAGEMENTTo be successful, organisations should create career paths that transform employees into safety leaders by ensuring that everyone is highly trained and motivated, not just to meet but to exceed expectations. The focus should be on developing a culture that supports the belief that every employee can create and maintain an illness & injury-free workplace. As a result, workers will feel ownership of the safety process and there would be a shift from an independent to an interdependent work culture.

According to Mehendale, unfortunately, using safety measures and safety equipment is considered a sign of being ‘non-macho’ by many workers. Such an outlook is

unfortunate, but sadly dictates the actions of people on the shop floor. Hence, it becomes important to explain to the people that the ‘macho’ thing to do is to adapt safety measures and return safe & sound every day to their homes. As the ABB senior management explains, “We should also not forget that excellence in safety is not just about saving lives; in the end, it also has positive impact on business performance, productivity and cost. Strong safety performance allows ABB to get better insurance rates for its projects, and makes risk reviews more accurate. And, many ABB customers include safety performance in their supplier evaluations.”

In the end, the culture of safety starts with an organisation’s leadership. Once this culture is established, safety becomes a way of life because it is being lived out by the firefighters each and every day.

[email protected]

SAFETY & SECURITY


S

1010 Ways to make your Workplace mishap-free

Ensuring proper safety and security of employees is of prime concern for most organisations. While the government has various Acts and legislations to ensure that the same is in place, its proper implementation at various workplaces is a must. Doing so will not only make the workplace mishap-free, but will also ultimately ensure overall growth of the organisation.

afety of employees at the workplace has been a major concern for the industry for a long time. However, for norms pertaining to safety and security to be effective, employees need to be aware of them. Here are some ways to

maintain the effectiveness of the prevailing safety & security management...

1IDENTIFYING AREAS, WHICH NEED SPECIAL ATTENTIONSpecial zones within plants from security point of view

need special attention irrespective of whether they meet or do not meet the required ergonomic design, the standards defined as per the Government of India or various state Acts. Safety and security managers & engineers should be present to measure the standards at the ground level.

2TRAINING AND EDUCATIONThere should be a safety & security cell within the industry,

which would train and educate employees. Attending the training-cum-seminars should be made mandatory.

3SAFETY AUDITSafety programmes as ongoing activities must be practiced

on a day-to-day basis. The safety auditor must take care of all these activities and ensure that everybody maintains the routine. This will change the attitude of employees towards unsafe acts and conditions.

4DEVELOP SAFETY FLOWCHARTSThere are different flowcharts, such as traditional

flowchart and technical flowchart, which are developed to ensure safety and security. While the technical flowchart today is robust enough to avoid even a minor accident, there is still a need to develop a flowchart, which would avert any mishaps.

5SOFTWARE SUPPORT TO MEASURE THE SAFETY & SECURITY STANDARDS

There are software solutions, viz., SAP, which are capable

of generating much accurate data if the right inputs are provided. The right inputs, however, can be collected during safety audits. Additionally, such data may further be used to enhance safety & security measures across the plant.

6CCTV & AUTO OPTICAL SENSOR MONITORINGSometimes, employees may forget to carry personal safety

equipment. In such a situation, an auto remote sensing software will generate a flag or bug to warn the management team.

7EFFECTIVE SAFETY REPORTINGThis is based on the fact that ‘one cannot apply what

one cannot measure’. Effective safety reporting stands for effective working of the above procedures, like effective and continuous monitoring and effective software support. The more effectively you collect the data, the more effectively you can apply it for future safety planning.

8INVESTIGATION OF SAFETY OCCURRENCESEven after developing a robust flowchart and implementing

it practically if there is a mishap, then there should be an inquiry on why the incident took place rather than who was responsible for it.

9INCENTIVE MECHANISMDifferent types of incentive schemes can be initiated in

order to promote safety and security at the workplace. But one must keep in mind that incentives are not the real mechanism to ensure safety and security; they are merely supportive mechanisms to increase awareness among employees.

10CONTINUOUS IMPROVEMENT OF THE OVERALL LEVEL OF SAFETY

Managing safety is not a one-day target. It is an ongoing activity that can be successful only through continuous improvement.

[email protected]

SUPRITA ANUPAM

NEW LAUNCHES

This section gives information about products, equipment and services available in the market. If you know what you want...refer to Product Index on Page 170 to find it quickly

LINEAR POTENTIOMETER

The Unilin–WT22 is push rod type linear potentiometer

having both side rod end bearing and one meter Tefl on lead

wires with silicon rubber sleeve for reliable and fl exible

connection. It is

available in

diff erent stroke

lengths from 50

mm to 300 mm.

Th is model is

specially developed for the injection molding machine application.

However it is also suited for general precision applications. Th e

sensors use a long-life (>2 million cycles) with conductive plastic

resistance element having linearity up to ±0.1 per cent and very low

noise in output.

Uni-Automation (India) Pvt Ltd

Pune - Maharashtra

Tel: 020-24420890, Mob: 09225573521


Website: www.uniautomation.com

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FACE MILLING SYSTEM

The Ceratizit MaxiMill 273 face milling system comes with

16 edged insert OAKU 060508 that has been upgraded.

Every insert has an integrated MasterFinish edge to

increase the surface quality achieved. With this MasterFinish edge

on the OAKU

customers can

generate surface

qualities of Ra

1.8 to Ra 2.5

depending on

the applied

cutting

parameters. Th e

MasterFinish cutting edge allows higher feed rates and guarantees

good workpiece surfaces. Maximum feed rate is 2 mm/rev. For even

higher surface requirements the newly developed a MasterFinish

insert is combined with the standard OAKU insert in one cutter.

Achievable surface quality is Ra 1.2 and better, depending on the

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applied cutting parameters. Th e XAHT MasterFinish insert has

two usable cutting edges.

Ceratizit India Pvt Ltd

Kolkata - West Bengal

Tel: 033-24940581


Website: www.ceratizit.com

DIGITAL PRESSURE SENSORS

The fl uid type PSAN series digital pressure sensor, realising

small size and 1/2,000 high resolution is newly introduced

to cover more diverse user applications, not only to cover

gas pressure but fl uid pressure

environments, as well. It

enables to provide various

functions including auto shift

function that makes stable

output possible regardless

of initial pressure change.

Furthermore, it is high

performance pressure sensor realising maximum 2.5 ms high-speed

response, 2 independent output function and normal open/normal

close output selection function. Th e connector type digital pressure

sensors are used for checking pressure of washing lines.

Autonics Automation India Pvt Ltd

Navi Mumbai - Maharashtra

Tel: 022-27814305, Mob: 09322902192


Website: www.autonic.in

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VEHICLE SECURITY AND TRACKING DEVICE

Tcop is a GSM-based vehicle

security and tracking device.

At the core of GSM-based

tracking solution is a proprietary

hardware device that has components,

like power adapter, antenna, central

processing unit, device software. Th e

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NEW LAUNCHES

device is fi tted in each of the mobile assets to be tracked and it

contains a GSM communication engine that stays in synchronised

contact with the GSM network, via SIM. Th e central processing

unit in the device runs on custom software that communicates with

the GSM network and gets location information from the nearest

GSM tower. Th is information translates into a user-readable format

and sends an SMS using the GSM network to a mobile phone.

iTrans Technologies Pvt Ltd

Bengaluru - Karnataka

Tel: 080-9742497, Mob: 09742497424


Website: www.tcop.in

SAFETY LIGHT CURTAIN

The safety light curtain is an opto-electronic device in the

form of invisible wall, which detects any unintentional

movement across it

and gives signal to be used

for activation of protective

circuits. Th is curtain is

mainly used for safety of

persons in machinery, which

has potential to cause harm.

Th e safety light curtain is

used as an alternative or

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addition to mechanical safety system and other form of traditional

machine guards. It is placed between an operator and the machine

so that if the operator puts any part of his body into the machine

unintentionally, then some of the optical beams get interrupted and

the receiver generates trigger signal for the controller section to stop

the machine.

Katlax Enterprises Pvt Ltd

Gandhinagar - Gujarat

Tel: 02764-286784


Website: www.katlax.com

GEARS/GEAR COMPONENTS AND ASSEMBLIES

A wide range of high-

precision gears, gear

components and gear

assemblies, both standard and

custom-built is available. Th e

manufacturing range includes:

spiral bevel gear sets: up to dia

457 mm and module 12.7,

hobbed gear: dia 500 mm x 8

m, hardened and profi le ground spur and helical gears: dia 330 mm

x 5 m, internal gears: dia 152 mm x 3 m, and custom built/non-

�


NEW LAUNCHES

standard gears and gear assemblies. Salient features include

intelligent design, superior raw materials and very high degree of

process discipline and lazor sharp quality assurance measures.

Applications are in machine tools, railways, textiles, automation,

automotive, engineering, pumps, compressors, printing machines,

etc.

Eppinger Tooling Asia Pvt Ltd

Coimbatore - Tamil Nadu

Tel: 0425-304000, Mob: 08870013053


RACK AND PINION

The TCG Runner non-backlash rack and pinion have

distinct advantage of non-backlash, high-precision, low

noise, less

vibration, low dust

generation, extended

length and smooth

running. Th e trochoidal

profi led tooth enables to

make a plurality of

mutual teeth mesh at

one time. Th e teeth

always mesh via two or three portions and eliminate backlash when

rotated in one or another direction. Rollers smoothly mesh with the

�


NEW LAUNCHES

PLATE MOULDING MACHINE

The DISA MATCH

20/24 horizontal

fl askless match plate

moulding machine is designed

and manufactured to deliver

high capacity of 160 un-cored

mould/hour. It is more precise

with maximum machine related

mismatch guarantee of 0.15

mm. Th e automatic core setter

(CSE) ensures repeatable and automatic core setting. Quick match

plate changer (QMC) enables easy and fast pattern change.

DISA India Ltd


Tel: 080-40201400


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optimised trochoidal tooth surface so as to avoid rattling noise,

tooth striking noise and rotating noise being induced together with

least amount of vibration. Applications are in gantry loader, robot

transfer in cleanroom, transfer equipment, plurality of heads,

robotic run at long stroke, etc.

Rotolinear Systems


Tel: 080-23572855, Mob: 09845196751


Website: www.rotolinearindia.com

PRECISION BEARINGS

The super precision bearing is used

for machine tools spindle.

Machine tool application require

superb performance in terms of running,

rigidity, stability, noise level, speed and

temperature stability. Running accuracy

class P4 and angular contact ball bearing

with phenolic cage. Th e high-precision

angular contact bearings, double row

cylindrical roller bearings and axial ball

bearings are designed to satisfy these demanding requirements by

machine tools. Angular contact ball bearings come in series of

metric 71800, 71900, 7000, 7200 and 7300; and double row

cylindrical roller ball bearings come in series of metric NN 3000

and NNU 4900.

Austin Engineering Company Ltd

Jabalpur - Gujarat

Tel: 02873-252223


Website: www.aec-bearings.com

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BARCODE READER

Model CR2 is the all-

application barcode reader.

Whether one is reading

smaller, high density 2D barcodes or

larger low density linear codes, the

CR2 outperforms all other scanning

devices. Th is barcode reader

incorporates a unique dual path optical

system, a 1.3 million pixel CMOS

sensor and a 400 MHz processor. It

features both a beep and vibrate mode,

multi-function LED indicators, two

top control keys and one handle (optional) control key. Th e barcode

reader scans data-matrix, QR code, PDF-417, Aztec code, RSS

composite and many more 2D barcode symbologies as well as all

linear barcodes. Standard USB interface provides plug-&-play USB

HID (keyboard) input for Windows 98, Me, 2000 and XP.

3S Industries

Mumbai - Maharashtra

Tel: 022-28213755


Website: www.3sindustries.com

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FIRE EXTINGUISHING SYSTEM

Bala-Wa CO

2 fl ooding

fi re extinguishing

system and

components are engineered,

designed, manufactured and

procured to meet NFPA-12 /

IS15528:2004 standards.

Independent CO2 cylinder

banks are considered for this off er to protect specifi ed area as per

specifi cations. High pressure CO2 systems consist of 68 litres W/C

seamless CO2 cylinder to fi ll 45 kg CO

2 gas, master and slave CO

2

cylinder valves, discharge and actuation hoses, CO2 frame assembly

with manifold, CO2 discharge nozzles, fi re alarm-cum-gas

discharge panel, manual gas discharge station, electronic hooter

with fl ashing lamp, discharge warning display board. Cylinder

banks consist of required nos of 45 kg gas capacity CO2 cylinders.

Agni Controls

Chennai - Tamil Nadu

Tel: 044-24812420


Website: www.balafire.com

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AIR BREATHING APPARATUS

The air breathing apparatus are used for working in smoke

and gaseous contamination of any degree or oxygen

defi cient areas. Th ese are widely used by various private and

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public sector undertakings. Th e air

breathing apparatus are available in

30 minutes and 45 minutes duration

cylinders.

Agni Suraksha Marketing Services

Delhi

Tel: 011-22775919, Mob: 09811117522


Website: www.endfireindia.com

SECURITY FENCE ENERGISER

Three lines of defence for protection of properties are off ered.

An actual demarcation line identifying the boundaries, in

which no further access is permitted. Th e highly visual

nature of these solar power fences and if necessary, the persuasion

of short sharp shocks are suffi cient in deterring casual would be

intruders. Alarm monitoring devices off er total gate and perimeter

protection. Alarm options, such as sirens, fl oodlights, etc, to ward

off , or silent alarms to allow the user to successfully apprehend the

intruder. Th e solar based security power fences are not only an

alternative to the other perimeter controllers, such as compound

wall, barbed wire fence, chain linked mesh, etc, but is in

incomparable in features it provides.

Alliance Solar Power Fences (P) Ltd

Hyderabad - Andhra Pradesh

Tel: 040-55610622


Website: www.controlwell.com

�

PORTABLE TOOLROOM

The portable toolroom is off ered as per needs of the

organisations. Mobility advantage can shift the toolroom

to the required shutdown area. All necessary spares and

accessories are safely stored for easy

retrieval at the time of breakdowns.

Instant availability at the plant area

saves time and labour, and help, in

quick functioning of the plant. Th e

toolroom is provided with heavy doors

and toughened glass windows for

safety and portability needs. Drawers,

racks, storage units, pullouts, airline,

AC/DC power supply, shot blasted to prevent corrosion at sensitive

locations. Heavy fl ooring is provided to withstand heavy job

handling required at the plant area.

Windoors India


Tel: 022-28518413


Website: www.windoors-india.com

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which are equipped with 24 hours monitoring with CCTV cameras

recording with the attempt of intrusion events. Th ese systems are

widely demanded in institutes, stock

yards, airports and production units.

Th e range of alliance security systems

provides 100 per cent protection

against theft, pilferage, arson and

sabotage. Th ese systems are designed

to suit individual security

requirements, and can also be

integrated with other security devices

like CCTVs, sirens and fl oodlights.

Th e system can delay and control all sorts of unauthorised intrusions

eff ectively.

Alliance Security Systems


Tel: 040-23404535, Mob: 09848124717


Website: www.controlwell.com

FIRE ALARM CONTROL PANEL

Multi-protocol intelligent fi re

alarm control panel (model

ZX1e) is designed and

constructed around proven and reliable

microprocessor technology. Th is simple

approach has produced a modular,

scaleable fi re alarm platform suitable for

protecting all types of premises. Th e fi re

alarm control panel supports a total of fi ve industry-leading

protocols, allowing fi re detection devices to be independently

selected based on performance or aesthetic appeal. Th e ZX series

control panel seamlessly integrates with Apollo (Xplorer, XP95 and

Discovery), Hochiki ESP, Nittan, Morley-IAS and system sensor

detection device protocols.

Security Vision


Tel: 022-24322727


Website: www.securityvision.com

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DIGITAL VIDEO RECORDER

This surveillance product called digital video recorder

(DVR) enables to develop integrated intelligent video

surveillance systems for security remote monitoring and

remote supervision. Audio/video doorphones, remote locks, metal

�SOLAR FENCE

A wide range of industrial sector security fences is designed

using high quality raw material. Th ese security fences are

basically designed for zone wise intrusion identifi cation,

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detectors are the products in security systems, which give optimum

services to customers. Currency counting machines are off ered for

bundles & loose currency, along with paper shredders and fake note

detectors. Th e paper shredders are security products, which gives

document security for businessmen & traders. Also available are

CCTV, security systems, inverters, EPABX, UPS systems; and

home appliances, like steam cooker, water heater & handy washing

machines.

Cannon Electronic Systems


Tel: 033-23700943, Mob: 09831016460


Website: www.cannonsecurity.co.in

LED DESTINATION SIGNS

The LED destination signs are used for public transit. Th ere

are no limits to the readability of LEDs both from the side

and from the bottom. Th e bus front signs are readable as it

gets closer to the stop and the side

sign is readable when people are

getting on the bus. Readability is

optimised, thanks to the increase

of contrast, due to the reduction of

the refl ected light. Bus destination

signs are readable in all light

conditions. Th e auto-adjustment of

the LED brightness, based on the

levels of the surrounding ambient light environment, guarantees

power consumption reduction while maintaining the readability of

information at optimal contrast levels.

B R Electronics


Tel: 044-22456925


Website: www.brimdisplays.com

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AXIAL FANS

These axial fans are available

in various types. Th e

characteristics of the fans

are to distribute air over a large area

with high air volumes and relatively

low static pressures. Th ese fans

feature very low profi les with

integrated single phase or 3-phase

external rotor motors. S-range axial

fans have sickle-shaped, individual

blades. Th e axial fans are designed to reach good effi ciencies even

with short orifi ce housings or simple wall openings. Accessories

include basket guard grilles, terminal boxes and wall rings. Th e

axial fans size ranges from 200 mm to 450 mm with air volume

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ranging from 400 m³/h to 6500 m³/h.

EBM Nadi International Pvt Ltd


Tel: 044-26720103


Website: www.ebmnadi.com

AUTOMATIC DOOR SYSTEMS

These systems open up

an almost unlimited

range of door design

options. Th e automatic swing

doors are characterised by a

simple assembly process and

can also be retrofi tted. Th ese

systems are modern, space-

saving and elegant. Th e systems combine architectural beauty with

functionality. Actuation devices are used to control and safeguard

the automatic door systems.

GEZE India Pvt Ltd


Tel: 044-30616900, Mob: 09884495610


Website: www.geze.in

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WIRES & CABLES

XLPE CABLES

The HT XLPE cables are available up to 33 kV (earthed

system). Conductors made from EC grade aluminium wires

are stranded

together and compacted.

All sizes of conductors of

single or three core cables

for HT cable are circular

compacted. Conductor

construction and testing

comply with IS:8130-1984

as amended up to date &

IEC:60228. Cables with copper conductor are also manufactured.

Conductor screening is provided for all cables above 3.3 kV grade in

the form of an extruded layer of semi conducting extrusion or semi

conducting tape over the conductor. High quality XLPE unfi lled

insulating compound of natural colour is used for insulation.

Gemscab Industries Ltd

Delhi

Tel: 011-42151572


Website: www.gemscab.com

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SUBMERSIBLE PUMP CABLES

These submersible pump cables are

specialised products used for

submersible pumps in deep wells.

Th e area of installation is physically

restrictive and the environment is very

hostile. Avocab cables are designed and

manufactured keeping in mind these

factors to achieve the highest possible

degree of reliability.

Chandresh Cables Ltd

Ahmedabad - Gujarat

Tel: 079-25623055-57, Mob: 9825006100


Website: www.avocab.com

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CABLE ORGANISER SYSTEM

The Cord Organix cable organiser

system is designed to address the

growing complexity of power,

data and audio/video cables. Th is cable

organiser system provides organised

solution to the tangle of cables hanging

behind every computer, LAN, audio/

video equipment, telephone system, etc.

Th e system is equally useful for

organising cables and cords of test and measuring equipment in

quality control department in factories. Th is easy-to-use cord

�

organiser system is designed to eliminate stress and manage cable

and cords in a neat and well-organised manner. Th e system

comprises of 6 carefully designed components through which any

one can organise the mess by bunching, holding, fi xing, identifying

and running cords on the desired direction.

Novoflex Marketing Pvt Ltd


Tel: 033-22260513, Mob: 09903163634


Website: www.novoflexgroup.com

COMMUNICATION AND AUTO CABLES

These are cables for automotive wiring harness, ignition

cables and battery cables that cover various sizes and

insulation materials for extreme temperature severities and

environmental condition.

Specially developed

communication and coaxial

cables are also available to suit

the individual requirement of

the customers. Applications are

in equipment like low loss

equipments, antenna cables, etc.

Paras Wires (P) Ltd

Bangalore - Karnataka

Tel: 080-28437205, Mob: 09845017044


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CABLE TESTING VAN

The cable testing van is equipped with all instrumentation

needed to locate faults on CU and optical fi bre cables

effi ciently and precisely. Any measurement needed for

inspection, evaluation, acceptance

tests and fault location on CU and

optical fi bre cable can be performed.

Th is van is used for inspection and

evaluation tests on CU cables, fault

location of interruptions and low-

resistive leakages with refl ectometer,

location of high-resistive cable faults

with cable measuring bridges,

location of cable sheath faults, cable

search, cable identifi cation, topographical surveying, searching for

markets, location of sleeves and loading coil pots, fault location and

attenuation tests with an optical backscattering device, etc.

PCI Ltd

New Delhi

Tel: 011-41888888


Website: www.primegroupindia.com

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WIRES & CABLES

PVC INSULATED CABLES

The PVC insulated cables are widely used for industrial

applications. Th ese cables are immune to moisture and are

tough but fl exible. Th e cables are easy to handle and install.

Regular PVC cables manufactured by the company are rated up to

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CABLES

These cables are off ered in

a wide range for

instrumentation, signal

and control. Th e cables are made

using various conductor

materials, like bare, tinned,

nickel plated copper and alloys

for thermocouple extension.

Th ese cables are screened with

braiding/Al-Mylar tape to avoid

interference from adjacent magnetic/electrostatic noises. Also

off ered are insulations with special features of FRLs properties up

to 1100 V grade, PTFE, silicon rubber and fi breglass insulation.

Thermopads Pvt Ltd


Tel: 040-23350577


Website: www.thermopads.com

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WIRES & CABLES

and including 1100 V and are manufactured according to IS:1554-

part-I-1988 or IS:694-1990. LT cables are manufactured according

to other standard or to customer’s specifi cations. Unless otherwise

specifi ed, PVC cables are manufactured using normal grade of PVC

suitable for continuous operating temperature of 70°C. However,

when asked for

special grade of

PVC cables, such

as heat resistant

cables suitable for

continuous

operating

temperature of 85°C or FRLs cables are also supplied as per

customers’ specifi c requirements.

Finecab Wires & Cables Pvt Ltd

Secunderabad - Andhra Pradesh

Tel: 040-27816588


RUBBER CABLES

The rubber cables

are available in a

wide range. Th ese

cables are used as heavy-

duty pliable armoured

trailing cables for opencast

and underground mines up

to and including 11 kV.

Cables are also used as

cables for portable drills

and jumbo drills, colliery lighting, for heavy-duty earth moving

machinery, for transportation and material handling machines,

stacker, reclaimer, etc.

Crest Cables Ltd

Secunderabad - Andhra Pradesh

Tel: 040-27538814


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PVC CABLES

A complete range of new

generation, low-cost

and high quality LT

PVC cables for voltage grade up

to and including 1100 V with

ISI mark (IS:694 and IS:1554

part I) is off ered. Th ese cables

are thoroughly tested at all

stages of manufacturing. Th e

cables are available both in

copper/aluminium conductors,

with solid/stranded, circular/

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WIRES & CABLES

shaped conductors. Th e range of products include polywrap winding

wire and three core fl at cables, specially suitable for submersible

pumps, single and multi-core fl exible cables for fi xed installations,

power and control cables, armoured and unarmoured type, house

wiring cables and wires, fl ame retardant and low smoke electric

wires, signaling cables, automobile and battery cables and other

special custom made cables.

Furcon Engineers Corporation

Jaipur - Rajasthan

Tel: 0141-2330411


POWER AND CONTROL CABLES

These power and control cables

include aluminium/copper

conductors, armoured/

unarmoured cables, etc. Th e cables

consist of carbon and hydrogen

compounds, which essentially contain

low-density polyethylene molecules in

the form of long fl exible chains. Cross-

linked polyethylene (XLPE) is a

thermosetting compound. It softens at

the crytahne melting point of

polyethylene (85°C to 115°C) and

assumes an elastic rubber like

consistency, a property that it retains

�

WIRES AND CABLES

A wide range of wires and cables is off ered for sensitive and

critical applications. Soft and fl exible wires come in 0.50,

1.0 and 1.5 sqmm conductor sizes off ering current rating

up to 15 A in industry

standard OD of 3.50

mm and in specially

formulated fl ame-

retardant ROHS

PVC. Th e inner

conductor is made out

of pure electrolytic

highly annealed

copper wires, which

is drawn, very fi ne

and bunched and

stranded with close pitch to realise an exceptional fl exibility and

fl ex life. Th e wires are used where fl exibility is a major requirement,

like in robotics, solar panels, instruments, multimeters, etc.

Allied Cables

New Delhi

Tel: 011-26311279


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WIRES & CABLES

HT CABLES

These HT cables are

available as per BIS,

BS, IEC or any

other international

specifi cations. Th e cables

come in 3.3 kV to 33 kV

grades. Th ese are also

available in single and 3

cores. Cross section area

ranges from 35 sqmm to

1000 sqmm. Conductors are

either aluminium or copper.

Insulation is XLPE.

Armours are of aluminum or

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during further rise of temperature until it becomes carbonised

without melting at 250°C to 300°C. All these strengthen the LT-

XLPE cables against stress cracking and give them a greater

resistance to fi ght ageing in hot air.

Empire Cable Industries Pvt Ltd

Delhi

Tel: 011-23867957


Website: www.empirecables.com


WIRES & CABLES

galvanised steel. Sheathing is HRPVC, FRLS, LSZH, etc.

Ravin Cables Ltd


Tel: 022-30816666, Mob: 09323947470


Website: www.primecab.com

DUAL SCREENED CABLES

A wide range of shielded screened cables designed for control,

power, data and instrument circuits is off ered. Standard

cable constructions are often insuffi cient for eff ective

installation in many situations. When a particular installation is

prone to EMI/RFI/ESI interference from either internal or

external sources, some form of shielding in the cable is necessary.

Only an aluminium foil or a tinned copper braid shield on its own

may not be eff ective, enough to eliminate or reduce the interference

problems in a cable. Hence the need for DataDShield cables,

wherein both an aluminium foil having 100 per cent coverage in

conjunction with a tinned copper braid shield is provided.

Sushil Cables Pvt Ltd


Tel: 022 26852239, Mob: 09819312887


Website: www.sushilcables.com

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HEATING CABLE

The model H3 heating cable is used for industries and

hazardous areas. Th is heating cable is also used for

maintaining temperatures in pipelines, so as to keep fl uids

in fl ow state. It is ideal for

process heating

requirements in oil and gas,

petrochemical, power,

chemicals and fertilisers,

metallurgical, cement,

pharma, food and edible oil

industries. Each length of

the heating cable requires

termination kits with cold

lead for power connection. Features include meet all test

requirements of EN50014 and EN50019, carry ATEX certifi cation

for use in hazardous area applications, provided with metallic braid

to make them mechanically strong and withstand hostile conditions,

generates the same rated heat output all along their length, and can

be used for heat up to 150°C and withstand temperature of 260°C.

Thermosystems Pvt Ltd


Tel: 040-23350577


Website: www.thermosystems.co.in

�


WIRES & CABLES

HEAVY-DUTY CABLES

These are LT XLPE/PVC

insulated power control and

instrumentation cables. Th e

XLPE insulated heavy-duty power

cables are off ered in 1.1 KV. Cross-

linked polyethylene (XLPE) is a

thermosetting material obtained by

forming cross linkages in polyethylene

molecules. Technical advantages include

higher current rating, higher short

circuit rating (approximately 1.2 times

than PVC), higher insulation resistance

(1000 times more than PVC insulating

cables), higher resistance to moisture

(1000 times more than PVC), better resistance to surge currents,

have better resistance to most chemicals, oils and acids, low

dielectric losses, better resistance to chemicals and corrosive gases,

comparatively higher cable operating temperature 90°C and short

circuit temperature 250°C smaller bending radius longer service

life.

Insucon Cables & Conductors Pvt Ltd

Jaipur - Rajasthan

Tel: 0141-2240557


Website: www.insuconcables.com

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GENERAL PRODUCTS

CYLINDRICAL ROLLER BEARINGS

These combined cylindrical

roller bearings are used for

all those applications where

self holders up systems for axial loads

are provided, like retractable lift

trucks. Th e main stud, on which

these bearings are mounted, is made

of high strength steel with good

welding properties. Radial bearings

off ered are long-life lubricated with

water repellant.

Spares & Components Co


Tel: 022-28831051


�

ELECTRO-HYDRAULIC GRAB BUCKET

A wide range of equipment and

components are off ered to fi t lifting

plants, according to the

requirements. Th e range includes bridge

cranes, gantry cranes, lattice jib cranes, etc.

Various types are available, such as 7000,

1.7100, 1.7200, 1.7300 range, suitable to

feed small incinerators for municipal waste

and to handle assimilated materials, for eg,

industrial waste, packing waste, wood waste,

having specifi c weight up to 0.7 T/mc. Th e

K-6500 range is suitable to feed big incinerators for municipal waste

and to handle assimilated materials.

Eddycranes Engineers Pvt Ltd


Tel: 022-23522710


Website: www.eddycranes.com

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FORGED/TURNED PROCESSED FASTENERS

These forged and turned processed fasteners are off ered as

per drawings or samples. Th e range includes A-25, A-42,

traub job, centreless grinding, thread rotting job, taping

job, knurled bush, hollow pins,

partly knurled pins, partly knurled

bush, small thickness lock nuts,

captive screws, pointed screws,

machine turning jobs. Materials of

construction are MS EN-1A, EN-

8, 6.6, 8.8 grades, EN-19, 10.9

grades or 10 K, EN-24, 12.9 grade,

brass, SS-304/316, etc.

Applications are in machine tools,

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light and heavy industries, automobile, textile, hydraulic,

pneumatic, electrical, electronics and other service industries.

ABC Industrial Fasteners


Tel: 022-2847 0806


Website: www.precibolts.com

GAS SAVER

The new gas saver promises to conserve energy and

economies’ on costs. Th is product is approved by the

government and has achieved the European standard CE.

Th e gas saver improves

thermal effi ciency of the gas

and off ers up to 25 per cent

gas saving. Th is device is

suitable for domestic,

commercial and industrial

use. Compatible gases

include hydrocarbons, LPG and CNG. Th e SVI gas saver has

undergone thorough scrutiny at a government laboratory by

National Small Industries Corporation Ltd (NSIC) in India,

ONGC approved Italab and at the Gas Appliances Research and

Development in Taiwan.

S Vagadia Innovatives

Dist Rajkot - Gujarat

Tel: +91-2827-254148, Mob: 09925125625


�

SURFACE GRINDING MACHINE

A wide range of precision hydraulic and manual surface

grinding machine is off ered. Th e design makes easy

movement of reciprocation table provided with V and fl at

guideway lining with Turcite–B for easy movement and hand

scraped to fi ne tolerance. Th e

manual surface grinding machine

has working surface with manual oil

dip of 225 mm x 450 mm / 300 mm

x 6oo mm and also hydraulic.

Wheel head spindle is hardened and

ground, runs on precision angular

contact bearings with imported

greece and driven by fl ange mounted

motor through fl exible couplings.

Wheel head micro feed is 0.002 mm.

Atul Machine Tools

Rajkot - Gujarat

Tel: 0281-6542034


Website: www.atulmachine.com

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GENERAL PRODUCTS

SLOTTED MACHINE SCREWS

Slotted-type machine screws with cold forged and hot forged

processes, round head, cheased head, CSK head, Philistar

head and fl anged-

type are off ered. Th ese are

made as per IS, BS, JIS,

ISO, GOST and DIN

standards or as per

customer’s drawings and

samples. Th reads can be

standard/coarse/fi ne pitch

mm size, BSW, BSF, BA,

etc. Applications are in

machine tools, light and

heavy engineering

industries, textiles,

electrical and electronics,

hydraulic, pneumatic, pumps, valves, bus body manufacturing, TVs,

videos, fans, photocopiers, telefax machines, home appliances,

washing machines, refrigeration, air-conditioners and other service

industries.

Zenith Industrial Products


Tel: 022-28470806


Website: www.zip-india.com

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GENERAL PRODUCTS

ARC WELDING TRANSFORMER

The model SH-

30 arc welding

transformer is

very eff ective for speedy

production, structural

work, machine building

and fabrications, fi lling

jobs, worn-out machine

parts repair and in arc cutting jobs. Design features include: modern

look, novel design concept; epoxy power coated body for long life

and coil varnishing by vacuum pressurized impregnating varnishing

system. Nominal current output is 300 A, primary voltage ranges

from 380 to 415, frequency is 50 Hz, maximum continuous hand

welding current at 60 per cent, and duty cycle is 300 A, etc.

Canary Electricals Ltd

Morbi - Gujarat

Tel: 02822-250431


Website: www.vulcanwelding.com

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GRP PIPES

These are manufactured by fi lament winding process with

effi cient engineering techniques. Standards followed are

IS:12709-1994 for potable water application, IS:14402

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PLASTIC PACKING BOXES

These plastic boxes

for cutting tools

are used for

industrial packaging.

Th ese are also used for

packing carbide tools, end

mills, reamers, tips, insert,

tap set, tool holder, etc.

Also off ered are foam, stickers, screen printing, emboss and

�

sewerage water application and

also followed by design standard

AWWA-M45. Th e pipes are

tested by effi cient testing

methods followed by specifi c

standards. GRP pipes are

technically advanced for all sewer

application with continued

benefi ts.

EPP Composites Pvt Ltd

Rajkot - Gujarat

Tel: 02827-287059


Website: www.atikagroup.com


GENERAL PRODUCTS

designing of logo of company on the boxes.

Om Manufacturer

Dist Rajkot - Gujarat

Tel: +91-0281-2384444, Mob: 09978500100


SPRING CLAMP TERMINAL BLOCK

An entire range of screwless

spring clamp terminal blocks

is off ered. Th is range of

terminal blocks provides

functionalities, like feedthrough,

multiple I/O, grounding and fuse.

Connections can be made using these

terminal blocks by simply stripping

the insulation of the wire and inserting it into the terminal. Th e wire

is held against the current carrying tin plated copper current bar by a

pre-stressed stainless steel spring clamp ensuring an oxidation-free,

low-contact resistance, gas-tight connection.

Connectwell Industries Pvt Ltd

Thane - Maharashtra

Tel: 0251-2870766


Website: www.connectwell.com

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GENERAL PRODUCTS

INDEXABLE CENTER DRILL

Nine9’s i-center indexable center

drill has new replaceable super-

hardened chip with high pressure

coolant supply through center drill that

enables high-effi ciency, shortens setup and

center drilling time and increases tool life

which reduces tooling cost. Th e tool holder

is suitable for both stationary and rotating

tools for VMC and turning centers.

Stitch Overseas Pvt Ltd

Gurgaon - Haryana

Tel: 0124-4755400, Mob: 09313361202


Website: www.stitchtools.com

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CORONA TREATMENT SYSTEM

The corona treatment system for narrow web and label

printing application is specially designed for easy push-pull

of ceramic electrode cartridges. Th e slim design

compliments the compact printing presses of today’s generation

thereby enabling easy installation and operator friendliness. With

its unique ultra-high effi ciency ridge profi le ceramic electrodes, the

corona treatment system eff ectively treats conductive as well on-

conductive substrates at high speeds. Th is system is supplied with

�

IEEC highly effi ciently ozone

extractor which can not only

remove ozone but also helps

develop a negative pressure on

the treating electrodes in order

to keep them cool during

operation. Th e system is

available in a variety of

confi gurations to cater to

varying applications and requirements.

PBJ Industrial Electronics Pvt Ltd


Tel: 022-28682283


Website: www.ieecpbj.com

SELF-OPENING DIE HEADS

Taco self-opening die-heads

(model SDH and SDG) are

thread cutting tools of a

single design to achieve mass

production with a uniform and high

accuracy. Th ese die heads are suitable

for cutting both right and left-hand

threads. Model SDH die head is

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GENERAL PRODUCTS

suitable for taking coventry chasers, while model SDG die head is

suitable to taking geometric style-D chasers, having threading

capacity from 2 mm to 30 mm in diff erent sizes. Th ese die heads

are used on automatic and semi-automatic lathe machines, turrets,

capstans and screw machines.

Tools & Appliances Corporation

Ahmedabad - Gujarat

Tel: 079-22740375


Website: www.imitoolsindia.com

NON-REVERSIBLE TAPPING HEADS

The model QCSFL non-reversible tapping heads are

specially developed for radial drilling machine and

reversible drilling and tapping machines. Th ese are also

suitable for large boring machines. Th e

chucks have an extensive tapping range

from M3–M42 comprising of 4 sizes. Very

easy in operation, these heads are versatile

in their usage. Equipped with radial

parallel fl oat, quick set torque mechanism,

compression + expansion enable the

operator to maximise productive without

breakage of tap. Th read profi le precision is

as guaranteed on these chucks. Th e tapping

heads are appropriate for LH and RH

threads.

Indmech Industrial Corporation

Dist Gandhinagar - Gujarat

Tel: 02764-233983, Mob: 09825146659



�

QUICK CHANGE CHUCKS AND ADAPTERS

The quick change chucks (model TF,

KD, KF and KT) are designed for all

types of drilling, lathes and boring

machines. Due to the nature of the simplistic

design, operators can easily perform multiple

operations, like drilling, reaming and tapping

with effi ciency and accuracy, not compromising

on quality of work. Tool change is made while the spindle is in

rotation and can be used for horizontal and vertical spindle machines.

Th ese chucks are appropriate for LH and RH threads.

IMI Machine Tools Pvt Ltd

Ahmedabad - Gujarat

�

Tel: +91-2764-233983




GENERAL PRODUCTS

SLIDING FOLDING DOORS

Ditec sliding folding doors are aluminium high-speed

folding doors that are pre-dominantly employed as

exterior doors for the hall exit. Th ese folding doors

provide protection against noise and

draughts; and also possess impressive

good heat retention and sound proofi ng

properties. Where designing modern

building exits, aspects like surface

fi nish, the division of leaves, rail

arrangement, colour bracing, insulation

and much more can be individually adopted to match the facade in

question. Th e doors have clear acrylic glass, if desired double-

glazed, which permits daylight to penetrate the building.

Gandhi Automations Pvt Ltd


Tel: 022-66720200


Website: www.geapl.co.in

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PLUG CONNECTION COUPLINGS

Phoenix Contact’s new

couplings for Variosub

plug connectors in D-

SUB 9, 15 and 25 formats

enable several D-SUB contact

inserts to be connected within

an IP67 industrial environment.

Push-pull locking makes for

smooth and simple operation.

Th e couplings can be used as a fl ying connection or be braced to a

wall mounting. Two integrated cable glands enable the separate

introduction of signal and power cables as well as the development

of line structures. T and X branches can be easily implemented with

the coupling. Pluggable coding profi les guard against improper

connections. Labelling plates guarantee quick identifi cation in the

installation unit. Customary D-SUB contact inserts for signals and

power are available using common connection technology as well as

easy-to-wire screw connections.

Phoenix Contact (I) Pvt Ltd

New Delhi

Tel: 011-30262800


Website: www.phoenixcontact.co.in

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HAND CLEANSER

Microcream is a creamy hand cleanser with unique

detergent and softening properties. Th e washing base is a

combination of ingredients, free of solvents and of other

substances harmful to the skin, but eff ective against dirt of any kind.

Macrocream also contains fi ne micro-spheres of vegetable origin

�


GENERAL PRODUCTS

LIFT TABLES

A wide range of Bolzoni Auramo lift

tables with their usual safety and

reliability features provide an

eff ective solution to most lifting problems. Th e

safety of the operator during the use of the lift

tables is paramount. All models include

aluminium safety bar, stopping descent of the

platform on contact with obstructions, safety

�

that strengthen the cleansing

action. Th anks to its pH it can

be used as many times as

needed, without causing any

reddening of the skin.

Macrocream is eff ective against

both greasy dirt and dry dirt.

Th e Macrocream is suggested

for repair shops, mechanics, tyre dealers, coach builders, plumbers,

blacksmiths, building and allied trading, metallurgical, mechanical,

mining, marine industries and petrochemical refi neries.

Arizona Company

Ahmedabad - Gujarat

Tel: +91-079-27700989, Mob: 09913607364



GENERAL PRODUCTS

BALL SCREWS

Hiwin high-speed ball

screws of the super S

series (cassette-type) fi t

for CNC machinery, precision

machinery, industrial machinery,

electronic machinery and other

high-speed machinery. Features include low noise (5-7 dB lower

than traditional ball screws), space-saving and weight-lightening

design, Dm-N value up to 180000, high acceleration and

deceleration velocity, accurate grade precision ground ball screws

available in JIS grade C0-C7, and rolled ball screws available in JIS

grade C6-C10.

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Luna Bearings


Tel: 022-23427671


Website: www.lunabearings.com

VIBRATORY SIEVE SHAKER

The new one-touch vibratory sieve shaker

has touch-screen programmable

controller that allows selection of

vibration level, time and pauses. It stores up to

99 testing profi les for easy repeat of standard

tests. Th e sieve shaker is a combination of

proven separation technology with the latest in

electronic control for fast and accurate

separation. Vibratory sieve shakers’ touch-

screen programmable controller allows selection

of vibration level, time and pauses. It stores up

to 99 testing profi les for repeat of standard

tests.

Cole-Parmer India


Tel: 022-67162222


Website: www.coleparmer.in

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clearance between scissors to prevent trapping during operation,

safety check valve to stop the lift table lowering in the unlikely

event of the hose break, protection against overloading, low voltage

control box with up-down buttons and emergency stop, maintenance

props (for safe maintenance operation), and removable lifting eyes

to facilitate handling and lift table installation.

Gandhi Automations Pvt Ltd


Tel: 022-66720200


Website: www.geapl.co.in


GENERAL PRODUCTS

V-BLOCK

The model JMV-205H V-block is used

for quality control toolrooms and

standard rooms. Th is V-block meets

all the requirements of the user. It has totally

three magnetic surfaces. Th e top and bottom

each with 90 degrees V angle and the end

surface is opposite to the switch. All three magnetic surfaces are

accurately ground and care has been taken, as such, that this can be

used in dry as well as wet machining operation. From quality

aspect, the accuracy for fl atness parallelism and squareness is within

5 microns. Th e permanent magnetic is housed in such a way that all

the three magnetic surfaces are activated simultaneously during ON

position of the knob.

Bombay Tools Supplying Agency


Tel: 022-23420522


Website: www.bombaytools.com

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CAM FOLLOWERS

These cam followers are designed to run directly on various

types of surfaces, such as cams, ramps and slideways.

Heavy section outer ring, and outer ring possessing no oil

hole or lubrication groove, prevents the introduction of impurities

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into the bearing and scaling and galling of

the bearing track. Convex outer ring

tolerates out-of-parallelism of contact

surfaces. Oil holes situated under the

needles enable lubricant replenishment

through the shaft. Full complement of

needles provides maximum dynamic and

static load capacities. Convex or cylindrical

outer ring is with/without inner ring.

NRB Bearings Ltd


Tel: 022-22664160


LASER MEASUREMENT INSTRUMENTS

The performance of today’s laser systems can strongly aff ect

the success of demanding, modern laser applications. Th e

beams’ size, shape, uniformity or approximation to the

expected power distribution,

as well as its divergence and

mode content can make or

break an application.

Accurate knowledge of

these parameters is essential

to the success of any laser-

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GENERAL PRODUCTS

based endeavor. As laser applications push the boundaries of laser

performance it is becoming more critical to understand the

operating criteria. Ophir-Spiricon has developed instruments to

accurately measure critical laser parameters. Th e new BeamGage,

software has led the new way.

New Age Instruments & Materials Pvt Ltd

Gurgaon - Haryana

Tel: 0124-4086513, Mob: 09555545224


Website: www.newagein.com

DISTANCE MEASURING DEVICE

Model DME 5000

distance measuring

device is used both in

automatic small parts warehouses as

well as high-bay warehouses for

pallets due to its various

measurement range models. Fast

and easy operation is possible due to

the illuminated display which shows

measurement value and status

information parallel. Th e mounting

bracket with three screw connections makes mechanical off set setting

possible and simplifi es installation and alignment. Equipment heating

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GENERAL PRODUCTS

and heatable refl ectors make use in cold-storage depots possible.

Sick India Pvt Ltd


Tel: 022-28227084


LIGHT INTENSITY MEASURING INSTRUMENT

The sensor of the light intensity measuring

instrument (testo 540) is adapted to the

spectral sensitivity of the eye. Th is is ideal

for the measurement of light intensity. Th e hold

function allows an easy readout of the measurement

values. Maximum and minimum values are displayed

at the press of a button. Th is is very handy, small and

easy to operate. Some of the specifi cations are hold

function and maximum/minimum values, including

calibration protocol, protective cap for safe storage,

including wrist strap and belt holder, sensor adapted

to spectral sensitivity of the eye, and backlit display.

Testo India Pvt Ltd

Pune - Maharashtra

Tel: 020-65600203, Mob: 09375346186


Website: www.testo-india.com

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ABS SHEETS

Acrylonitrile butadiene styrene

(ABS) is made of a hard and a

soft phase whose interaction

yields a combination of diff erent

properties. Th is ABS is a modifi ed

styrene acrylic nitride (SAN) for

enhanced mechanical properties, however still retaining some basic

properties, such as small shrink factor. Th e ABS sheet has high-impact

strength with a textured hair-cell fi nish on one side. It can be sawed,

routed, glued and heat formed. Black colour sheets are available and

other colours are off ered on request. Th ickness ranges are 0.2, 0.9, 2, 3,

5, 6, 8, 10 mm and sizes available are 4’ x 8‘, 1.5 m x 2 or 3 m.

Sangir Plastics Pvt Ltd


Tel: 022-28726120


Website: www.sangirplastics.com

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CONTINUOUS MONITORING SYSTEM CONTROLLERS

The continuous monitoring system controller is a wall

mountable controller (500-W) which is microprocessor based

system with inbuilt self test facility. It has a two user that is

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GENERAL PRODUCTS

PUMP CLEANING MACHINE

The high-pressure pump cleaning machine

is used for big sump cleaning

applications. It sucks the metal chips,

dust debris and coolant to the top of the tank.

Th en the coolant is fi ltered by special fi lters inside

the collection tank system. Features include

strong heavy-duty metal frame impact resistant

plastic injection covers, convenient storage for

gun and lance, small size for storage and practical

to use, thanks to its vertical design, easy to move

even on steps and over bumpy ground thanks to

its two large wheels (a 220 mm) and its handle in a particularly

ergonomic position, simple to transport horizontally in the car, low

pressure detergent system with regulation pressure gauge.

Powerjet Engineering

Dist Thane - Maharashtra

Tel: 0250-6454169


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settable with latching alarm set points and one

fault alarm. It has three relay contacts, viz for

low alarm, high alarm and fault alarm

conditions. Th e 7-segment LED display shows

instantaneous gas concentration. It is compatible

with 4-20 mA inputs from both two-wire and

three-wire transmitters. Th e relay inhibits

switch and reset switch for resetting the alarm

LEDs. It has 4-20 mA loop back signal.

Uniphos Envirotronic Pvt Ltd

Dist Valsad - Gujarat

Tel: 0260-2730156, Mob: 09909994063


Website: www.uniphos-she.com

Godrej & Boyce Mfg Co Ltd


Tel: 022-67964363, Mob: 09920113138


Website: www.godrej.com

ANTI-VIBRATION TABLE

The anti-vibration table is eff ective for

isolation of precision equipment from

fl oor generated vibrations by

environmental means. It is used for

applications where instrument where instrument usage and accuracy

of readings are aff ected by vibrations, like weight balances,

galvanometer and more. Th e table is made from a tubular frame with

cover panels, kaddapa with granite top and with antistatic rubber

pads at the bottom. Load capacity of the frame is 250 kg UDL.

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INTERNATIONAL PRODUCTS

SERVO MOTORS

A wide range of high-performance servo motors, which

include SVM, SPM, SVMA series, linear motors (LPM

series) and

torque motors are

designed and

manufactured to

worldclass standards.

Th ese servo motors

are used in a variety

of machines, which

include injection

moulding machines

and blow moulding machines, press punching machine, packaging

machine, etc. With high refl ection, low torque and low electric

energy, a series of servo motors provide effi cient performance to

keep wide power output. With high compatibility, servo motors are

available in various brands of inverters and drivers, such as Siemens,

Mitsubishi, Yaskawa, Fanuc, CT, etc. For saving energy cost, servo

motors which are used in injection moulding machines save 30-70

per cent electric energy.

Cheng Chang Machinery Electric Co, Ltd

Taichung City - Taiwan

Tel: +886-4-25624099


Website: www.solpower.com.tw

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POWER VICE

The MC power vice has pressure constant. Th e clamping

force is presetting-type. Th e same clamping force is

repeatedly used. Th e vice body is made of ductile iron

FCD-60. Vise bed is hardened to HRC45-degrees and maintains

accuracy for long. Th e vise bed height-size and the guide block sides

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GREASE MANUAL LUBRICATOR

These are CLHP grease manual

lubricator and KSC electric

grease lubricator for plastic

extrusion machines, press and

woodworking machines. Th ese are easy to

operate by hand and can be easily

installed. Capacity ranges are 300 cc, 600

cc, 800 cc, 1,000 cc, and 2,000 cc. A level

switch can be added on request. Also off ered are various types of

lubricators, oil systems, fl uid grease system, distributors, oil pumps,

motors, accessories and fi ttings. All products are tested and verifi ed

by TÜV and have CE of machinery safety directive certifi cate.

Changhua Chen Ying Oil Machine Co Ltd

Taichung Hsien - Taiwan

Tel: +886-4-26393751


Website: www.chenying.com.tw

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are all made with full control, with 2, 3, 4 vices to perform a fob at

a time. Th e length of the vice body is very short, but the clamping

range is very big. It works with every kind of milling machine,

CNC machine centre.

Jin Year Precision Co, Ltd

Taichung City - Taiwan

Tel: +886-4-25232817


Website: www.jinyear.com.tw

CHAIN HOISTS

These stainless steel chain hoists are

made of SS304 and SS316 series

stainless steel. Th e clean room hoist

products are well-suited for lifting applications

in wash-down, environmentally-controlled

and corrosive processing environments. Th ese

are available in standard capacities up to 2 MT

and feature sealed gearing, foodgrade

lubrication and stainless steel hooks.

David Round, Inc

Ohio - USA

Tel: +1-330-6561600


Website: www.davidround.com

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TRIPOD ROBOTS

The Festo tripod robots have created instantaneous re-

calibration of workpiece types a reality at the press of a

button. Th ese robots manage production with an IFC

fl exfeeder system that feeds components through the production

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NC ROTARY TABLE

FibroPlan NC rotary table is characterised by the very

extensive capabilities of the rotary table movement and

angular positioning, both under full CNC-control. Th e

rotary table is used on machine tools

of diverse type and description, with

the control of their rotational axis

provided either by an additional

control axis of the machines’ CNC, or

by a separate CNC unit for the rotary

table itself. Th e rotary table attributes, together with drive and

control elements of outstanding quality.

Fibro GmbH

Weinsberg - Germany

Tel: +49-7134-730


Website: www.fibro.com

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process. Th is simple integration, including the resulting new

possibilities for instant process variability, is a practical example of

the company’s vision moving towards process automation and

integration. In line with this vision, Festo has developed a simple

control system for the tripod robots that allows easy

parameterisation and confi guration of new variants programmed

using the teach-in function.

Festo AG & Co KG

Ostfildern-Scharnh - Germany

Tel: 49-711-3474032


Website: www.festo.com

MODULAR SAFETY CONTROLLER

The central component of the fault-tolerant programmable

logic controller is the new QS001CPU microprocessor

module. Th is central processing unit (CPU) has a secure

architecture with two processors and

supports up to 6,144 remote I/O points

and up to 14K program steps. Memory

capacity for up to 3,000 system and

error messages makes safety processes

transparent and allows fast and detailed

analysis in the event of malfunctions.

Th e controller’s power supply unit is installed on the module rack

next to the PLC processor module.

Mitsubishi Electric Europe BV

Ratingen - Germany

Tel: +49-2102-4864190


Website: www.mitsubishi-cnc.de

�

DRILLING MACHINE

Quickmill’s Intimidator G-series drilling machine is used

for large part machining, for performance and simplicity.

Designed and built to provide the best value in both

milling and drilling solutions, the

high horsepower machine is sure to

hit a home run for users. Features

include: Fanuc 21i control, 75 HP

(56 kW), 4000 RPM, through

spindle coolant, etc. Options are:

probes, rotary indexers, right angle

head, hydraulic part clamping, 1000

PSI coolant, twin spindles, etc.

Quickmill Inc

Petersborough - USA

Tel: +1-705-7452961


Website: www.quickmill.com

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ALUMINIUM FLOORING PROFILE

The FN power pro aluminium fl ooring profi le is extremely

stable and durable. Th is aluminium fl ooring profi le is

available in the form of transition, motion, end and stair

profi les and can be used for

all common types of fl oor. It

is available in laminated and

solid veneered with overlay or

anodised forms. A range of

innovative installation

systems guarantees rapid, easy

and professional assembly to

suit every pocket. Th e fl exible

fl ooring profi les, FN pro-fl ex

are regarded as a milestone in

profi le production.

Neuhofer Holz GmbH

Zell am Moos - Austria

Tel: +43-6234-85000


Website: www.fnprofile.com

�

THERMAL IMAGING SYSTEMS

The models GS100 and GS110 thermal imaging systems are

used for quality control in glass processing applications.

Model GS100 system is an automated infrared temperature

measurement system for glass bending, forming, annealing and

tempering processes.

Th e systems detect

defects quickly and

automate quality

monitoring for ISO-

9000. Th e GS110

system incorporates

all of the features of

the GS100 system. It

is suited for

monitoring and optimising of glass treatment processes. Coated

glass has very low emissivity values. By quickly detecting thermal

irregularities within the glass and identifying defective heating

elements, the GS110 allows glass processors to improve product

quality and uniformity and reduce scrap.

Raytek GmbH

Berlin - Germany

Tel: +49-30-4780080


Website: www.raytek.de

�

The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of

SEARCH

v

ABROAD

4-6 May 2012INTERNATIONAL MACHINE TOOLS EXPO (IMEX)Focus: Machine tools and allied productsWhere: Chennai Trade Centre, ChennaiTel: 022 2839 8000Fax: 022 2839 0502E-mail: [email protected]

17-18 May 201211th ANNUAL GREENTECH SAFETY AWARD & CONFERENCE 2012Focus: Latest developments in fire, safety & securityWhere: Visakhapatnam, Andhra PradeshTel: 011 49030000E-mail: [email protected]

9-11 May 2012GREENBUILDINGFocus: Energy efficiencyWhere: Verona Exhibition Centre, ItalyTel: +39 0439 84 98 55E-mail: [email protected]

NATIONAL

EVENT LIST

v

5-8 July 2012AUTOMOBILE WORLD SHOWFocus: AutomobileWhere: University Ground, Ahmedabad, GujaratTel: 079 26469725, 26460624Fax: 079 26403087

27-30 July 20128TH AMTEX 2012Focus: Machine toolsWhere: Pragati Maidan, New DelhiTel: 080 43307474 Mob: 098867 89641Fax: 080 22352772E-mail: [email protected]

10-12 July 2012ROBOTICS ASIA 2012Focus: Robotics & automationWhere: Putra World Trade Centre, Kuala LumpurTel: +603.6140.6666Fax: +603.6140.8833E-mail: [email protected]

ABROADNATIONAL

v

ABROAD

8-10 JUNE 2012TECHNO4Focus: Medium & light engineeringWhere: CODISSIA Trade Fair Complex, Hall ECoimbatoreTel: 0422 2220014, 4216020Fax: 0422 2223076E-mail: [email protected]

14-18 June 2012ACMEE 2012Focus: Manufacturing technologyWhere: Chennai Trade Centre, ChennaiTel: 044 2625 8619E-mail: [email protected]

21-24 June 2012MANUFACTURING EXPO 2012Focus: Manufacturing technology Where: BITEC, Bangkok, ThailandTel: +66 2686 7222 Fax: +66 2 686 7266 E-mail: [email protected]

NATIONAL

v

ABROAD

16-18 AUGUST 2012ENERGEX’12Focus: Energy equipment & heavy fabricationWhere: Vestry School, Trichy, Tamil NaduTel: 0431 2410641Fax: 0431 2410656E-mail: [email protected]

2-5 August 2012QINGDAO MACHINE TOOLS & MOULDS EXHIBITIONFocus: Tools & tooling equipmentWhere: Qingdao International Convention & Exhibition Centre, Qingdao, ChinaTel: +86 0532 55552936Fax: +(86) (532) 55552903

22-24 August 2012 SHANGHAI INTERNATIONAL ASSEMBLY AND HANDLING TECHNOLOGY EXPOSITIONFocus: Automotive manufacturingWhere: Shanghai New International Expo Centre (SNIEC), Shanghai, ChinaTel: +86 21 6468 1300 / +86 21 6468 1550 Fax: +86 21 3416 0018E-mail: [email protected]

NATIONAL

v

NATIONAL

7-10 September 2012AUTOMATION 2012Focus: Industrial & factory automationWhere: Bombay Exhibition Centre, MumbaiMob: 9819872165E-mail: [email protected]

27-30 September 2012INDIA MANUFACTURING SHOW 2012Focus: Manufacturing and engineering industry Where: Hall 1 & 2, Bangalore International Exhibition Centre, Bengaluru Mob: +91 98440 68250E-mail: [email protected]

10-15 September 2012INTERNATIONAL MANUFACTURING TECHNOLOGY SHOW (IMTS)Focus: Manufacturing technologyWhere: McCormick Place, ChicagoTel: 800 828 7469 Fax: 703 827 5250 E-mail: [email protected]

ABROAD

EVENT LIST

AHMEDABAD October 5-8, 2012

PUNE November 2-5, 2012

CHENNAI November 22-25, 2012

LUDHIANA December 21-24, 2012

Tel: 022-30034651 • E-mail: [email protected] • Web: www.engg-expo.com

INDORE January 11-14, 2013

AURANGABAD February 1-4, 2013

RUDRAPUR February 23-26, 2013

v

NATIONAL

4-6 October 2012INDIA STEEL 2012Focus: Technology, machinery & equipment in the steel industry Where: Bombay Exhibition Centre, MumbaiMob: +91 9899392930Email: [email protected]

30 October - 1 November 2012WIRE & CABLE INDIA 2012Focus: Developments in wire & cable Where: Bombay Exhibition Centre, MumbaiTel: +91 (0)11 2697 1745/1056 66E-mail: [email protected]

3-5 October 2012POWER-GEN ASIAFocus: Power generationWhere: Impact Exhibition & Convention Centre, Bangkok, ThailandTel: +44 1992 656 634E-mail: [email protected]

ABROAD


MMS 2012

s this decade unleashes the exponential growth of the Indian machine tools industry—as expected and witnessed in the

global market—the second edition of Modern Machine Shop (MMS 2012) was successful in bringing to the fore the significant role played by small-scale industries in this ever-evolving journey. Held during April 5-8, 2012, the event was inaugurated by Arvind Kapur, President, ACMA; Vikram Sirur, President, IMTMA; RD Madan, Chairman – Regional Council (North), IMTMA and V Anbu, Executive Director, IMTMA. Speaking on the occasion, Kapur said, “This event is vital for the machine tools industry. It reaches out to all the regions of the country where manufacturing activities actually take place.”

MMS 2012 displayed a variety of technologies, including metalworking machinery, low-cost automation, material handling, quality control systems & equipment, software and consultancy & off-the-shelf production aids, which facilitate modernisation in manufacturing organisations. Explaining the reasons for organising MMS 2012 in the northern region, Anbu informed, “The region generates about 40% of the total machine tools demand in India.” In addition to this, Sirur said, “We want to make companies aware of all the latest machine technologies and capabilities available in the market. Our goal is to maximise the productivity levels of all manufacturing companies and we are content with the response generated in

this edition.” The event also witnessed various high-level delegations from companies such as North Central Railway, COFMOW, ACMA, Ordnance Factory Board, BHEL and Hero Motors, among others.

USPs The second edition of MMS 2012 was special in more ways than one. Discussing the uniqueness of MMS 2012, VS Goindi, Past President, IMTMA, said, “We made special arrangements for engineering students so that they could attend our show and gain exposure to the machine tools industry. This initiative played a key role in further improving their technical capabilities.” Anbu added, “In addition to machine tools, there were several innovative solutions on display that would enable the whole manufacturing process achieve higher levels of productivity.” Highlighting another unique feature of this year’s edition, Sirur stated, “This MMS show made

young professionals aware of the latest developments, machine capabilities and quality controls, which can help them serve their customers better. Further, the show bridged the expectation gap between OEMs and their vendors.”

VISITORS’ VOICEThis business-to-business exhibition provided a new platform in terms of forging new partnerships between engineering professionals, system integrators and customers. Visitors were impressed with the state-of-the-art technology & equipment on display. Ajay Bhanot, GM – Operations (Lighting Fixtures), Havells India, opined, “Havells always aims at expanding the production areas by implementing newer & innovative technologies and platforms like Modern Machine Shop give us scope to look out for such technologies. We came here to look for systems like turret punch presses and press brake tools, which we can easily procure locally from Northern

A nation’s industrial growth depends on many factors, including market demands & dynamics, newer technologies and companies, products & service offerings, exchanging ideas and inspirations, forging ties…the list is an exhaustive one! The second edition of Modern Machine Shop (MMS) delivered all this and more under one roof. Going by industry sentiments, the four-day trade show, held during April 5-8, 2012, enhanced the prospects of maximising metalworking scope and opportunities for one & all. A report…

A

Maximising Metalworking Scope

TARUN TAMPI & ARINDAM GHOSH

IMTMA President Vikram Sirur sets the tone for MMS 2012 with his inaugural speech


MMS 2012

India. More exhibitions like Modern Machine Shop should take place in this region, as it will play a key role in giving more exposure to manufacturers based here. However, I believe that more awareness-related initiatives are required towards popularising such industrial shows and demos should be incorporated on the shop floor itself.”

Adding to Bhanot’s perspective, Parvez Alam Gaur, Regional Manager – North, Magnaflux, Division of ITW India, informed, “Presently, the show is in a nascent stage. However, over a period of time, it will become a major show for the manufacturing industry. Here, one gets to learn about the latest technologies available in the market, on one platform. I came here to primarily look for material handling systems like automated conveyors.”

BEHOLDING TREMENDOUS POTENTIALIndia is set to become one of the Top 5 global machine tools markets over the next five years and events, like MMS 2012, with global participation, will play a critical role in helping India move forward in this direction. The event featured about 100 stalls with several live demonstrations, as well as overseas exhibitors representing six nations, including Austria, China, Japan, Netherlands and the US. The four-day event also witnessed an influx of about 5,000 visitors representing local and national businesses, educational & research institutes as well as government organisations.

Presently, two-thirds of the entire machine tools demand in India is met through imports. To lower this fraction, exhibitions like MMS will play a crucial role. Sirur said, “2012 is a significant year for us as it marks the beginning of the 12th Five Year Plan for the manufacturing industry. This lays down the vision to increase our share from 16% to 25% by 2025. Such events witness better partnerships,

advanced technologies and increased business, thus building momentum & business confidence.”

EXPANDING REACHIMTMA plans to take the exhibition to other parts of the country and expand its reach on a regular basis. “The event is a one-stop shop for engineering SMEs. It aims to bring together an entire array of machines, equipment, products and services,” informed Sirur, adding, “We propose to organise such exhibitions every year, particularly in those centres where industries are setting up their manufacturing base.” Commenting on the expansion plans, Anbu said, “This year, we focussed on Delhi and the National Capital Region. We have already made plans to expand the presence of our show. In the coming year, we intend to hold two more editions of the show in Mumbai and Chennai along with Delhi.”

COMPETING WITH CHINA It has been an established fact that China is making efforts to grab a major share of the pie by bringing in low-priced solutions. In such a scenario, India needs to strengthen its machine tools base such that it is not only able to compete in terms of quality, but also in terms of price. Goindi explained that a country should have a strong machine tools industry to support the growth and expansion of the country’s manufacturing demands. The Chinese Government strongly supports the growth of the machine tools industry, where manufacturing contributes nearly 50% of the GDP; unlike in India, where manufacturing contributes just 15–17%. On similar lines, Sirur opined that an Indian machine tools builder holds an advantage in India, as the company can immediately attend to the problems of a customer within India, as compared to their international manufacturers in India. Elaborating on tough competition from Chinese companies, Anbu stated that, presently, in terms of technology, reliability and customer service, Indian companies have an edge over their Chinese competitors. However, he also cautioned that Chinese companies are improving their quality and their technology offerings and that too, at competitive prices. In order to tackle this situation, Indian companies need to work harder, he suggested.

CONNECTING THE DOTSThe show not only bridged the

expectation gap between OEMs and their vendors, but also helped SMEs gauge the magnitude of competition coming from neighbouring countries. All in all, the event was a resounding success. With greater national awareness and an expansion of coverage of MMS, SMEs can successfully forge together a future for the Indian manufacturing industry from the grassroot level in the years to come.

Special focus on technology and innovation to drive competitiveness, especially for SMEs

Improve quality and productivity at every stage of manufacturing

Upgrade machine and job shops Provide manufacturing fl exibility

to accommodate shorter product lifecycles

Educate and encourage SMEs to move up the value chain

OBJECTIVES ACHIEVED

ACMA President Arvind Kapur and IMTMA Past President NK Dhand review the products displayed

PRODUCT INDEX


ABS sheets 154

AC gear motor 6

AC motor 57

AC servo motor 6, 67

AC variable frequency drive 61

AC/DC panel 147

Accessories 10

ACCLs 63

Acoustic enclosure 157

Aerobridge installation and maintenance 149

Air breathing apparatus 118

Air-operated diaphragm pump 146

Airport equipments and service provider 149

All geared auto feed pillar drilling machine 120

Allen cap and csk 153

Alloy steel cold drawn seamless straight

pipes and tubes 129

Alu-cera polymer 9

Aluma coat 9

Aluminium oxide ceramic composites 9

Aluminium worm geared motor 178

Analogue DC drive 165

Analogue 149

Annunciators 131

Anti-vibration table 156

Appliance switches 25

Arc welding transformer 142

Attendance system 149

Auto-feed radial drilling machine 120

Automatic door systems 125

Automatic drain valve 137

Automatic rolling shutter 23

Automatic weighing system 149

Automation devices 71

Automation 97, 179

Automotive wire 186

Autophoretic coating 129

Axial fans 124

Axial flow fan 129

Ball bearings 16, 113, 145

Ball roller bearing 16

Product Pg No

Ball screws 150

Band saw blade 115

Barcode reader 118

Battery charger 165

Battery operated pallet truck 123

Bearings 16, 122, 145

Belt conveyor 71

Bench grinding machine 158

Billet shearing machine 18

Bollard 23

Brake motor 57, 140, 178

Building automation 179

Burnishing drill 20

Burnishing reamer 20

Burnishing tool 20

Cabinet unit (single skin/double skin) 129

Cable carrier 122

Cable conduit 25

Cable connector 122

Cable gland 55, 89, 125, 141

Cable organiser system 126

Cable testing van 126

Cable ties 55, 89, 125, 141

Cables 63, 129

Cage mill dryer 68

Calendering roll FGF

Calibration equipment thermowell 152

Cam followers 148, 152

Carbide single roller burnishing tool 20

Carbon steel 129

Carbon steel cold drawn seamless

straight pipe and tube 129

Cargo system and sort equipment 149

Cast and extruded products 115

Casting 7

Castors 112

CCTV solution analogue and IP 149

CED coating machine 179

Centerless OD burnishing machine 20

Centrifugal fans 185

Centrifugal pump 39

Product Pg No

Ceramic adhesive cement 9

Ceramic electrical heater parts 9

C-frame power press 18

Chain pulley block 140

Chain 122

Chamfering tool 20

Channel magnet 127

Chemlok coating machine 179

Chlorine gas cylinder/tonner 88

Circular/gyrator vibro machine 127

Clamp 134

Cleaning equipment 173

CNC cable 164

CNC cutting machines 179

CNC laser cutting machines 179

CNC lathe 29

CNC machine 104, BIC

CNC oxyfuel and plasma cutting machine 179

CNC turning center 104, BIC

CNC turret punch press 134

CNC vertical machining center 104, BIC

Coating machine 179

Coating plant 179

Coating system 179

Coating 129

Coaxial cable 186

Cobum centerless OD burnishing machine 20

Cold drawn seamless straight pipes

and tubes 129

Cold form section 119

Cold galvanising 129

Cold storage dockhouse 23

Cold storage door 23

Cold-drawn seamless U-tubes and pipes 129

Commercial vehicle 21

Communication and auto cables 126

Compensating cable 152, 156

Compressed air system fittings 26

Conceptline wall mounted enclosure 49

Cone pulley heavy-duty lathe machine 145

Cone pulley light-duty lathe machine 145

Product Pg No

Looking For A Specific Product?Searching and sourcing products were never so easy.

Just type SRCH (space) Product Name

and send it to 51818eg. SRCH Pump and send it to 51818

PRODUCT INDEX


Cone pulley medium-duty lathe machine 145

Connector 10, 41, 122

Construction electric hoists 81

Contactor 63

Container pump 146

Continuous monitoring system controllers 154

Control cabinet 41

Control cable 156

Control panel accessories 25

Control panel 41

Control system 41

Control technology 24

Conventional precision lathes 29

Conveyor chain 22

Conveyor 112

Conveyors and automation systems 23

Cooling pad 135

Cooling systems 139

Cooling tower motor 178

Corona treatment system 146

Corrosion preventives 53

Counter current spray dryer 68

Counter flow cooling tower 130

Counter 131

Crab hoist 140

Crane-duty motor 140, 178

Cranes 8, 81, 116, 140

Cross connection accessories 10

Cushion dock shelters 23

Cutting machines 179

Cutting tool FGF

Cylindrical roller bearings 138

Dampers for centrifugal fans 129

Data cable 164

DC motor 57

Deburring tool 20

Demagnetiser 124

Desktop accessories 161

Diamond burnishing tool 20

Didactic equipment for training 41

Digital DC drive 165

Digital frequency meter 125

Digital pressure sensors 110

Digital video recorder 119

Product Pg No

Dip spin coating machine 179

Distance measuring device 153

Distribution board 12

Dock leveller and shelter 23

Double drum and triple drum

magnetic separator 124

Drawer magnet 124, 127

Drill 120

Drilling machine 120

Drive technology 24

Drive 27

Drum pump 146

Drum-type magnetic separator 127

Dry vane pump 157

Dual screened cables 134

Electric actuators 86

Electric forklift truck 23

Electric wire rope hoist 81, 130, 140

Electrical and electronic products 117

Electrical and maintenances contractor 149

Electrical control panel 165

Electrical measuring instruments 147

Electrical products 55, 61, 89, 125, 141

Electro magnetic vibratory feeder 127

Electro-hydraulic grab bucket 138

Electroless nickel plating 129

Electronic components 117

Electronic timer 30-36, 131

Electronics product 55, 89, 125, 141

Electropnematic positioner 160

Element shrink disc 148

Embossing rolls FGF

Emergency safety kit for cylinder/tonner 88

End clap and shop 10

End plate 10

Energy efficient motor 178

Energy meter 131

Engineering class chains and sprockets 22

Engineering plastic plug and socket 30-36

Engineering plastic product 154

Engineering plastics 115

EOT crane 81, 130, 140

EOT jib crane 8

ER for external corner radius burnishing 20

Evaporator 68

Product Pg No

Exhibition – Acmee-2012 114

External roller burnishing tool 20

External spherical surface burnishing tool 20

Extruding 7

Fabricator and turnkey projects 149

Face milling system 110

Face plate 164

Facility management 149

Factory automation 179

Fasteners 153

FBE and nylon coating 129

Files 161

Financial institute 77

Finishing machine 127

Fire alarm cable 186

Fire alarm control panel 119

Fire extinguishing system 118

Fire shutter 23

Fixtures 134

Flameproof motor 57

Flange mounting motor 57

Flash dryer 68

Flat cable 156

Flat high-tension single-twin

igniting electrode 9

Flexi panel 50

Flexible conveyor system 71

Flexible wire 186

Floor heating mat 159

Flow meter 146

Fluidised bed coating machine 179

Force actuation 132

Forged/turned processed fasteners 138

Forging press 18

Forging 10

Forklift truck 111

Free-flow conveyors 71

Freewheel-oneway-clutch 148

Frequency meter 147

Friction drop hammer 18

Friction screw press 18

Fuel storage 155

Fully threaded bar 153

Funnel magnet 127

Gantry crane 8, 140

Product Pg No

PRODUCT INDEX


Gap frame press 99

Gas chloronical gravity and vacuum feed 88

Gas engine 121

Gas saver 138

Gear box 130, 163

Gear coupling 148

Gear motor 130, 163

Geared head heavy-duty lathe machine 145

Geared head medium-duty lathe machine 145

Geared motor 140, 163

Gears/gear components and assemblies 112

Glide coating machine 179

Glide wheels 112

Goliath crane 81, 140

Gomet bearing 113

Goods lift 8

Grab bucket 81

Grill magnet 127

Grinding machine 158

Grinding media 9

Grip plier 134

Group marker holder 10

Growth capital and equity assistance

for MSMEs 77

GRP pipes 142

Hacksaw blade and frame 115

Hammers 18

Hand cleanser 148

Hand magnet 127

Handling system module 41

Hard chorme plating 129

Heat resistance coating 129

Heat transfer equipment 185

Heat treatment salt 53

Heaters 124, 152

Heating cable 134

Heat-shrink tubing 55, 89, 125, 141

Heavy industrial steel structure 119

Heavy-duty bearing 116

Heavy-duty cables 137

Heavy-duty CNC 153

Heavy-duty cycling duical bearing 113

Helical gearbox 130

Helical inline geared motor and reducer 163

Helicol insert 164

Product Pg No

Heli-worm geared motor 178

Hex bolt 153

HF and RF coaxial cable 156

H-frame power press 18

High-alumina wear-resistant ceramic tile 9

High-efficiency standard motors

flameproof motor 178

High-intensity rare earth magnetic

separator 127

High-intensity roller-type

magnetic separator 127

High-pressure blower 185

High-pressure jet clean equipment 48

High-speed door 23

High-temperature control cable 152

High-temperature copper conductor

equipment wire 152

High-temperature insulation

LT power cable 152

High-temperature thermocouple cable 152

HMM technical guidelines 178

Hoist 81, 116

Hold back 148

Hollow saw kits and accessories 115

Home appliances 63

Hooper magnet 124, 127

Horizontal CNC machine 104, BIC

Horizontal handle clamp 134

Horizontal machining centre 104, BIC

Hospital equipment 48

House wire 83

HRC fuse body 9

HSS tools bits & cutoff blades 115

HT cables 133

Human machine interface 61

Hump magnet 124, 127

Hydraulic components 26

Hydraulic cylinder 162

Hydraulic dock levellers 23

Hydraulic dock shelters 23

Hydraulic forging hammer 142

Hydraulic manual pallet truck 123

Hydraulic press 99, 142

Hydraulic seal 93

Hydraulic shearing machine 99

Product Pg No

I/O plate 164

I/P transducer 160

IC counter balanced forklift 23

Imaging and vision system 179

IMTMA - AMTTF 128

IMTMA - Finishing school 136

IMTMA - Productvity summit 144

Indexable center drill 146

Induction heater 28

Inductive proximity switch 25

Industrial automation products 61

Industrial automation 97

Industrial ceramic 9

Industrial data logger and bespoke solution 133

Industrial electric power distribution system 12

Industrial fan and blower 129

Industrial grinding and cutting 7

Industrial overhead doors 23

Inline drum type magnetic separator 127

Inline helical geared motors 178

Inline shaft mounted helical geared

motors and reducers 163

Instrumentation and control 14, 15

Instrumentation cable 156

Instruments 125

Insulated cable 159

Insulated door 23

Insulated wire 159

Intelligent Ethernet system 133

Interface modules and accessories 10

Interface modules 10

Interference-free PC board 133

Interlocking door 23

Internal radius burnishing tool 20

Internal roller burnishing tool 20

Inverter 67

Inverter-duty motor 178

IR for internal corner radius burnishing 20

Isolator 103

ISPH internal spherical

surface burnishing tool 20

Jib crane 140

Jigs 134

Joining 132

Junction box 49

Product Pg No

PRODUCT INDEX


Keyless transmission element 148

Kits and components 164

Kuman machine interface 67

Ladder 48

Laptop accessories 161

Large diameter welded pipes 137

Large helical and heli-bevel gearbox 178

Laser measurement instruments 152

Lathe machine 145

LED destination signs 124

LED signal tower light 30-36

LEDs 25

Level controller 109

Lift tables 149

Lifting magnet 124

Light intensity measuring instrument 154

Lighting system 155

Limit switch box 86

Limit switch 32-36, 160

Linear potentiometer 110

Liquid ceramic coating 129

Liquid filling machine 20

Liquid pump 146

LLDPE tube 26

Load break switch 25

Loader 111

Loading bay equipment 23

Lorry loader 111

Low lift pallet truck with ride 23

LPS high-tensile fasteners 164

LR tools for long and deep holes 20

Magnetic coolant separator 127

Magnetic floor sweeper 127

Magnetic pulley 124

Magnetic rack 124

Manual chain hoist 116

Manual pallet truck 23

Marker plotter 10

Markers 10

Material handling equipment 123, 140, 149

MCBs 103

MCCBs 63

Measuring instruments 147

Metal cutting tool 5

Product Pg No

Metal treatment chemical 53

Meters 147

MGM brake motor 85

Micro milling bead 9

Micro PLC 67

Micro switch 30-36

Mill lining block 9

Modular PLC 67

Motion control 67, 143

Motor and pump protection relay 109

Motor control centre 165

Motor protection circuit breaker 25

Motor 57

Motorised boom barrier 23

Motorised vibratory feeder 127

Motors and drives 97

Moulded cable 186

Moulding machine 7

Mounting bracket 10

Mounting rails 10

Multi-apartment 149

Multi-core flexible cable 156

Multi-core round cable 186

Multi-level car parking systems 149

Multi-level steel car parks 119

Multi-speed motor 178

Needle roller bearing 113

Network 24

Networking rack 149

Non-reversible tapping heads 147

Non-setting gasket & jointing compound 141

Nuts 153

OD burnishing machine 20

ODS fillets or contours shoulders 20

OEM supplier of suspension components

for automobile FIC

Office lighting 63

Ohms meters 147

Oil seals 162

ON/OFF ball valves 86

ON/OFF butterfly valves 86

ON/OFF control valves 86

ON/OFF plug valves 86

O-rings 93

Overband magnetic separator 127

Product Pg No

Overhead door 23

Paint and plating instrument 150

Paint shop equipment 179

Paint shop machines 179

Pallet stacker with ride on operators 23

Panel board 124

Panel meter 125

Panel 147

Panels wire 164

Paper/nomex/mica covered conductor 83

Parallel shaft helical geared motors 178

Part ejector 79

Partition plate 10

Patch cord 164

PBEGL geared motor 57

PCM cable 156

Pedestrian and rider operated counter

balanced pallet truck 123

Pedestrian low lift pallet truck 23

Pedestrian pallet stacker 23

Permanent magnetic chuck 124

Permanent magnetic drum pulley 127

Permanent magnetic drum type separator 124

PF controller 125

Phase failure relay 109

Phase monitoring device 131

Pick and move crane 111

Pick and place system 71

Pillar drilling machine 120

Pilot light 25

Pipe tube fittings 26

Pipes and tubes 129

Piping system 26

Piston GP hole burnishing machine 20

Planning machine 153

Plano milling machine 153

Plastic packing boxes 142

Plat truck 112

Plate magnet 124, 127

Plate moulding machine 116

Platform 48

PLC and PC based automation system 165

Plotter accessories 10

Plug connection couplings 148

Plugs and sockets 25

Product Pg No

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PRODUCT INDEX


Plumbing pipes and fittings 26

Pneumatic actuator 86

Pneumatic components 26

Polyacetal 115

Polypropylene 115

Polyurethane 115

Portable coolant purifying system 79

Portable oil skimmer with variable speed 79

Portable toolroom 118

Power and control cables 132

Power distribution panel 165

Power distribution 155

Power line transducer 125

Power magnet 124

Power monitoring relay 109

Power press 99

Power rental 155

Power system 139

Power transmission chains and sprockets 22

Precision bearings 116

Precision fabrication works 134

Precision switch 25

Pre-engineered metal building 119

Press brake machine 99

Press technology 132

Pre-treatment system 179

Process automation and control equipment 41

Process gas blower 185

Product designing 151

Proline modular (floor-mounted) enclosure 49

Protective cover 10

Protective polymer coating 129

Proximity sensor 30-36

PTFE tape 159

PTFE 129

PTFE/Teflon 115

Pull action clamp 134

Pump automation product 109

Pump cleaning machine 156

Pump 39, 146, 157, BC

Punch press 134

Pure water fitting 26

Push button 25

PVC cables 130

Product Pg No

PVC control cable 152

PVC flap door 23

PVC flat cable 83

PVC insulated cables 129

PVC strip door 23

Pyrometers 152

Quick change chucks and adapters 147

Rack and pinion 115

Radial drilling machine 120

Radio remote controls 133

Rapid flexible door 23

Rapid roll-up door 23

RCCBs 103

Reach truck 23

Real-time Ethernet system 133

Real-time open source PAC system 133

Rear cylinder hydraulic press brake 99

Reciprocating & jig saw blades 115

Re-crystallised alumina tubes 9

Relay 117

Remote controls for industrial applications 133

RFID equipment system & reader 149

Ribbon wires 164

Right-angled helical bevel geared

motor and reducer 163

Right-angled helical worm geared

motor and reducer 163

Robo palletisation 71

Roller conveyor 71

Roller type magnetic separator 127

Roofing and cladding sheet 119

Roots blower 157

Rotary atomiser 68

Rotary dry vacuum pump 185

Rotary shaft seal 93

Rotary switch 25

RTD cables 152

RTDs 152

Rubber cables 130

Rubber products 162

Rust preventives 53

Safety light curtain 112

Safety protection device 25

Salt spray chamber 150

SCADA and DCS implementation 179

Product Pg No

Scissor lift 23

Screw compressor 160

Screw presses 142

Screw thread inserts 164

Seals 162

Seamless pipe 137

Sectional overhead door 23

Security fence energiser 118

Self-opening die heads 146

Self-tapping and machine screws 153

Sensitive part loading and unloading 79

Sensor solution 143

Sensor technology 24

Separator plate 10

Servo drive 61

Servo motor 61

Servo system 139

Shaft loading 79

Shearing machine 99

Shielded cable 156

Short and lower adjustment range tools 20

Shot blasting and peening machine 107

Shrink wrapping machine 20

Shunts 147

Side holding plate 10

Silence flow package 185

Single and multiple precision switch 25

Single limit switch 25

Single-point braze carbide tools 115

Sizing and finishing tools 20

SKB skiving and roller burnishing tools 20

Slat conveyor 71

Sleeve bearing 113

Sliding folding doors 148

Slipring crane-duty motor 57

Slotted machine screws 141

Small size ball bearing 113

SMPS system 131

Sockets and switches 10

Soft starter 109

Solar fence 119

Solderless terminal 55, 89, 125, 141

Solid carbide drill and mill 5

Solid carbide reamer 5

Solid carbide special drill and mill 5

Product Pg No

PRODUCT INDEX


Aluminium flooring profile 164

Chain hoists 160

Drilling machine 162

Grease manual lubricator 159

Modular safety controller 162

NC rotary table 160

Power vice 159

Servo motors 159

Thermal imaging systems 164

Tripod robots 160


Product Pg No

Solid carbide special reamer 5

Sorting systems & automation 149

Spat shot peening adjustable

multi-roller burnishing tools 20

Special application motor 178

Special-purpose machine 153

Special-purpose process machinery 71

Spin flash dryer 68

Spot cooler 135

Spot face roller 20

Spray dryer 68

Spring clamp terminal block 145

Squeezing roll FGF

SR carbide single roller

burnishing tool 20

SR single roller burnishing tool 20

Stainless steel fasteners 153

Stainless steel pipe 137

Stair lift 149

Stationary products 161

Steel mill duty & flame proof cranes 81

Straight line action clamp 134

Structural floor decking sheet 119

Submersible pump cables 126

Submersible winding wire 83

Super enamelled winding wire copper

and aluminium 83

Super precision bearing 113

Superior hard anodising 129

Surface grinding machine 138

Suspension magnet 127

Switchboard meter 147

Switches 63, 103, 117

Switchgear 97

Tachometer 131

Tail lift 23

Tapeasy articulated arm tapping machine 20

Taper hole roller burnishing tool 20

Taper shaft burnishing tool 20

Technical ceramic 9

Telephone cable 156

Telescopic door 23

Temperature controller 131

Tensioner nut 148

Terminal block 10

Product Pg No

Testers 147

Textile and yarn trolley 48

Thermal imager 152

Thermal imaging camera 177

Thermocouple extension 152

Thermocouple 152

Thermostats 124

Three-core flat cable 156

Thrust ball bearing 113

Time switch 131

Timer 109

Toggle action clamp 134

Toggle press 134

Tool bit 115

Torque motor 178

Tower crane 111

Track rollers 148

Transformer 147

Trap magnet 127

Trolley wheel and caster 48

Trolley 112

Truck blower 185

Tube 137

Tubing accessory 41

Turret punch press 134

UHMW-PE 115

Unbrako 164

Universal radial drilling machine 145

Used CNC turret punch press 134

U-tube 137

Vacuum booster pump 157

Vacuum system 157

Valve positioner 86, 160

Valve terminal 41

Valve 41, 137

Varistor cabinet 49

V-block 152

Vehicle security and tracking device 110

Vertical handle clamp 134

Vertical order picker 23

Vertical turning lathe 153

VGA cable 164

Vibrating motor 127

Vibrating reed type 147

Vibrating screen machine 127

Product Pg No

Vibratory bowl 127

Vibratory sieve shaker 150

Videodoor phone IP 149

Vision technology 143

V-series cooling technology 49

Water faucet and tap parts 9

Waterjet cutting FGF

Welded pipe 137

Wheel assembly 130

Wheel barrow 112

Wheel 112

Winch 8, 81

Wire connector 55, 89, 125, 141

Wire rope drum 130

Wireless crane control 133

Wires and cables 132

Worm drive hose clamp 154

XLPE cables 126

XLPE/PVC power cable 83

Xylan coating 129

Zinc flake coating 129

Zirconia polycrystal ceramic 9

Product Pg No

ADVERTISERS’ LIST


Our consistent advertisers

Acropolis Engineering Ltd 133

T: +91-22-26441180

E: [email protected]

W: www.acropoliscranes.in

Action Construction Equipments Ltd 111

T: +91-11-40549900


W: www.ace-cranes.com

Aiema Technology Centre 114

T: +91-44-26258731


W: www.acmee.in

Alliance Engineering Company 148

T: +91-22-24112461


W: www.allflexcouplings.com

Amsak Cranes Private Limited 8

T: +91-44-26273486


W: www.amsakcranes.com

Apex Industries 129

T: +91-2764-291085


W: www.industrialcoatingsindia.com

Applied Engg Services 116

T: +91-20-24448165


W: www.appliedengg.in

Aqua Services 88

T: +91-265-2331748


W: www.aquaservicesindia.com

Ashok Industry 116

T: +91-22-2623 2133


W: www.ashokindustry.com

Avasara Technologies Ltd 71

T: +91-80-2608 3300


W: www.avasarala.com

Avcon Controls Pvt Ltd 53

T: +91-22-61504150


W: www.ashokindustry.com

Baumer India Pvt Ltd 143

T: +91-20-30515000


W: www.baumer.com

Bhagirath Heavy Transmission 130

T: +91-11-32222661


To know more about the advertisers in this magazine, refer to our ‘Advertisers’ List’ or write to us at [email protected] or call us on +91-22-3003 4640or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better

Advertisers’ Name & Contact Details Pg No Advertisers’ Name & Contact Details Pg No Advertisers’ Name & Contact Details Pg No

Bonfiglioli Transmissions (Pvt) Ltd 27

T: +91-44-67103800


W: www.bonfiglioli.com

C&S Electric Ltd. 103

T: +91-11-30887520-29

W: www.cselectric.co.in

Canara Engineers Pvt Ltd 130

T: +91-22-29203849


W: www.canaraindia.com

Chamunda Equipments 134

T: +91-79-27522437


W: www.chamundaequip.com

Chetan Cabletronics (P) Ltd 186

T: +91-1493-513109


W: www.chetancable.com

Classic Polymers & Resins 115

T: +91-22-24465251


W: www.classicpolymers.com

CNP Pumps India Pvt Ltd 39

T: +91-22-25818400


W: www.nanfangpumps.com

Coatec India 179

T: +91-172-5063436


W: www.coatecindia.com

Connectwell Industries Pvt Ltd 10

T: +91-251-2870636


W: www.connectwell.com

Control Engg Co 61

T: +91-33-2248 0192


W: www.cecoelectronics.co.in

Desiccant Rotors International Pvt Ltd 135

T: +91-124-4188888


W: www.drirotors.com

Durga Bearing Pvt Ltd 113

T: +91-22-6876073


W: www.durgabearings.com

Eddycranes Engineers Pvt Ltd 81

T: +91-22-2352 2710


W: www.eddycranes.com

Electronic Automation Pvt Ltd 131

T: +91-80-42802345


W: www.eaplindia.com

Emaar Impex Pvt Ltd 117

T: +91-22-23854163


Everest Blowers 157

T: +91-11-45457777


W: www.everestblowers.com

Festo Controls Ltd 41

T: +91-80-22894100


W: www.festo.com

Filex Systems Pvt Ltd 161

T: +91-09899258121


W: www.filexindia.com

Flir Systems India Pvt Ltd 177

T: +91-11-4560 3555


W: www.flir.com

Forging Machinery Manufacturing Co 18

T: +91-161-5011755


W: www.nkhhammers.com

G W Precision Tools India Pvt Ltd 5

T: +91-80-40431252


W: www.gwindia.in

Gandhi Automations Pvt Ltd 23

T: +91-22-66720200


W: www.geapl.co.in

GE Energy 121

T: +43 5244 600-0


W: www.gejenbacher.com

Gemco Controls Ltd 165

T: +91-129-2274831


W: www.gemcocontrols.com

Ghaziabad Flopal Insulation Pvt Ltd 159

T: +91-09650924190


W: www.indiamart.com/flopol/

Girish Ego Controls 124

T: +91-22-22068032


W: www.girishego.com

ADVERTISERS’ LIST



Jyoti Ceramic Industries Pvt Ltd 9

T: +91-253-2350120/338


W: www.jyoticeramic.com

Jyoti Cnc Automation Pvt. Ltd. .BIC

T: +91-2827-287081


W: www.jyoti.co.in

Karcher Cleaning Systems Pvt Ltd 173

T: +91-120-4661800


W: www.karcher.in

Khandelwal Cables Ltd 83

T: +91-09412286105


W: www.polywin.in

Klipco Pvt Ltd 154

T: +91-22-28684221


W: www.klipcoclips.com

Knowell International Pvt Ltd 145

T: +91-33-22304627


W: www.knowell.co.in

Kumbhojkar Plastic Moulders 154

T: +91-20-24450055


W: www.kumbhojkarplastics.com

Luthra Pneumsys 26

T: +91-09821128362


W: www.pneumsys.com

Macro Tech Equipment Pvt Ltd 123

T: +91-33-24666261


W: www.macrotechcal.com

Mahindra & Mahindra Ltd (Auto) 21

T: +1800-22-6006


W: www.mahindrasmallcv.com

Makson Machines Pvt Ltd 120

T: +91-278-2446437


W: www.makwanaeng.com

Mech-India Engineering 20

T: +91-22-25853293/ 22-2585 3293


W: www.mechindia.com

MGM-Varvel Power Transmission (P) Ltd 85

T: +91-44-64627008


W: www.mgmvarvelindia.com

Minilec (India) Pvt Ltd 109

T: +91-20-22922354


W: www.minilecgroup.com

Girish Radio Corporation 164

T: +91-11-23874297


W: www.girishradiocorp.com

Goliya Electricals Pvt Ltd 147

T: +91-22-24120456


W: www.goliya.com

Goliya Instruments Pvt Ltd 125

T: +91-22-24149657


W: www.goliyainstruments.com

Grundfos Pumps India Pvt Ltd BC

T: +91-44-24966800


W: www.grundfos.in

Havells India Ltd. 63

T: +1800-11-0303;011-41660303


W: www.havells.com

Hensel Electric India Pvt. Ltd. 12

T: +91-44-24541669


W: www.hensel-electric.de

Hi-Fab Valve Automation 86

T: +91-22-40766539


W: www.hi-fab.com

Hindustan Motor Mfg Co 178

T: +91-22-42500500


W: www.hindmotors.com

Igus India Pvt Ltd 122

T: +91-80-39127800


W: www.igus.in

IMTMA 128; 136; 144

T: +91-80-66246600


W: www.imtma.in

Inventum Engineering Co Pvt Ltd 28

T: +91-22-26730499


W: www.inventumindia.com

J J Gandhi Chemicals Pvt Ltd 141

T: +91-22-40972525

Jaibalaji Control Gears Pvt. Ltd., 30-36

T: +91-44-26251279


W: www.jaibalaji.firm.in

Jaykrishna Magnetics Pvt Ltd 127

T: +91-79-22970452


W: www.magneticequipments.com

Advertisers’ Name & Contact Details Pg No Advertisers’ Name & Contact Details Pg No

Mitsubishi Electric India Pvt Ltd 67

T: +91-124-4630300


W: www.mitsubishielectric.asia/india/

N K Enterprises 104

T: +91-22-29201175


W: www.msenggindia.com

National Institute Of Design 151

T: +91-79-26621109


W: www.designclinicsmsme.org

NI Systems India Pvt Ltd 14; 15

T: +91-80-41190000


W: www.ni.com

Nia Controls 160

T: +86-574-8833-6868


W: www.augustcompressor.com

NMTG Mechtrans Techniques Pvt Ltd. 148

T: +91-79-22821527


W: www.nmtgindia.com

Oil Seals Mfg Co Pvt Ltd 162

T: +91-22-22047943


OSG India Pvt Ltd 7

T: +91-20-66304407/08

W: www.osg-india.com

Parashield Corporation 156

T: +91-11-22592741


W: www.parashieldcorpn.com

Patels Airflow Ltd 129

T: +91-79-40200800


W: www.steeltubeinida.com

Pentair Technical Products India Pvt Ltd 49

T: +91-80-28454640


W: www.pentairtechnicalproducts.com

Perennial Technologies Pvt Ltd 155

T: +91-20-22953511


W: www.powerrental.co.in

Pilz India Pvt Ltd 24

T: +91-20-24213994


W: www.pilz.in

Power Build Ltd 163

T: +91-2692-231070


W: www.pbl.co.in

Advertisers’ Name & Contact Details Pg No

ADVERTISERS’ LIST



Precihole Machine Tools Pvt Ltd 6

T: +886-3-329-9968


W: www.peei.com.tw

Prem Brothers 158

T: +91-11-28117456


W: www.powermaster-india.com

Premier Engineering Technics Pvt Ltd 149

T: +91-22-26852233


W: www.premiertechnics.com

Presto Stantest Pvt Ltd 150

T: +91-129-4272727


W: www.prestogroup.com

Raajratna Ventures Ltd 153

T: +91-79-27561915


W: www.raajfasteners.com

Ravi Electronics 160

T: +91-79-65722609


W: www.fluconautomationinc.com

Renu Electronics Pvt Ltd 50

T: +91-20-27292840


W: www.renuelectronics.com

Rexello Castors Pvt Ltd 112

T: +91-22-40917777


W: www.rexellocastors.com

Rightvision (India) Pvt. Ltd. 142

T: +91-120-4261026


W: www.rightvision.biz

Sanyo Denki Singapore Pte Ltd 139

T: +-91-44-42038472


W: www.sanyodenki.com/ad/search1201

Sarabsukh Enterprises 153

T: +91-1871-223893


W: www.sarabsukhmachines.com

Sawalka Tools & Machines India Pvt Ltd .FIC

T: +91-20-27474447


W: www.sawalka.com

Shachi Engineering Pvt Ltd 68

T: +91-20-66546900


W: www.shachiengg.com

Shailesh Sales Corporation 99

T: +91-281-2461102


W: www.shaileshmachines.com


Siemens Ltd 97T: +91-22-27623727E: [email protected]: www.siemens.com

SLN Technologies Pvt Ltd 133T: +91-80-26651659E: [email protected]: www.slntechnologies.com

Small Industries Devt Bank Of India 77W: www.sidbi.com/growth.asp

Sonal Magnetics 124T: +91-79-22872349E: [email protected]: www.sonalmagnetics.com

Spareage Seals Ltd 93T: +91-22-25800972E: [email protected]: www.spareage.com

Spares & Components Co 16T: +91-22-25800972E: [email protected]: www.spareage.com

Sumitron Exports Pvt Ltd. 55; 89; 125; 141T: +91-11-41410631E: [email protected]: www.sumitron.com

Suraj Limited 137T: +91-79-27540720E: [email protected]: www.surajgroup.com

Surface Finishing Equipment Co 107T: +91-291-2740259E: [email protected]: www.surfacefinishing.com

Swam Pneumatics Pvt Ltd 185T: +91-120-4696222E: [email protected]: www.swamatics.com

Syp Engineering Co Pvt Ltd 146T: +91-22-28489969E: [email protected]: www.sypco.co.in

Techaids .FGFT: +91-172-4379995E: [email protected]: www.techaids.in

Teknic 25T: +91-22-26592392E: [email protected]: www.tecknic.co.in

Tempsens Instruments (I) Pvt Ltd 152T: +91-294-3052953E: [email protected]: www.tempsens.com

The Indian Electric Co 57T: +91-20-24475845E: [email protected]

W: www.indianelectric.com


TIDC India 22

T: +91-44-42235509


W: www.tidcindia.in

Tox Pressotehnik India Pvt Ltd 132

T: +91-20-66538300


W: www.tox-de.com

Trident Pneumatic Pvt Ltd 137

T: +91-422-2401376


W: www.tridentpneumatics.com

Trident Products Pvt Ltd 162

T: +91-124-4300626


Trident Tools Pvt Ltd 115

T: +91 22 2884 7191


W: www.magicut.net

Tussor Machine Tools Ind P Ltd 29

T: +91-422-3200183


W: www.pinachoindia.com

United Netlink Pvt Ltd 149

T: +91-20-26345274


W: www.netlinklive.com

United Steel & Structurals Pvt. Ltd 119

T: +91-44-42321801


W: www.unitedstructurals.com

U-Tech Associates 79

T: +91-80-23390309


W: www.u-techindia.com

Venus Engineers 140

T: +91-11-32222661


W: www.venusengineers.com

Vinit Engimech Pvt Ltd 145

T: +91-281-2312091


W: www.balajilathe.com

Vishal Indtl Traders 164

T: +91-22-23447975


W: www.vitraders.in

Weldor Engineering Pvt Ltd 134

T: +91-2827-252038


W: www.weldorpunchpress.com

Wont Industrial Equipments 48

T: +91-261-2894847


W: www.wantindia.com


RNI No: 67827 /98 Postal Regd No G 2 / NMD / 81 / 2011 -13Posted at Mumbai PatrikaChannel Sorting Office- GPO, Mumbai 400 001

on 22nd & 23rd of Every Previous Month Date Of Publication: 18th of Every Month

188

RNI No: 67827 / 98 Licensed to Post without prepayment License No: WPP - 246Postal Regd No: KA / BG GPO / 2564 / 2011-13Posted at MBC, Bangalore GPO on 25th & 26th of Every Previous MonthDate of Publication: 18th of Every Month.

Vo

l 15 No

05

May 2012

search - may 2012

Documents

trapped workers

edition of search

trapped productivity

enhanced safety needs

safety incentive mechanism

safety leadership imperatives

new age safety gears

incident workplace